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Service and Maintenance Manual

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1. R21 2 SPEED CUTOUT Figure 3 15 Updated 10 98 3 34 JLG Lift Wiring Diagram Standard Ford Lrg425 Dis Engine W Standard Controls Sheet 1 Of 2 3120240 SECTION 3 TROUBLESHOOTING CHEKA SOME VALVES ARE SUPPLIED WITH GREEN GROUND WIRES ISI VARIABLE RELUCTANCE SENSOR CRANK POSITION ENGINE COOLANT TEMP SENSOR DISTRIBUTORLESS LECTRONIC GOVERNOR INGITION COIL El JLG P N 1600211 ESSI TAN WHT 18 TAN ORN 18 EXISITING FORD UNIVERSAL ELECTRONIC CONTROL PLUG rej PEE PEZAN AUXILIARY RELAY WOTE THE RED 14 GA FUSIBLE LINK IS DESIGNED TO ACT AS A FUSE DURING DIRECT SHORTS THE FUSIBLE LINK SHOULD BE ROUTED SO THAT IT LS NOT TOUCHING ANY COMPONENT THAT COLD BE DAMAGED IF IT MELTS THE LINK SHOULO BE LOCATED IN FREE AIR x OVER NOTE EED LOCKOU ABOVE ELAY BLOCK n 12 VOLT DC BATTERY STARTER MOTOR 1282459 A Figure 3 16 Wiring Diagram Standard Ford Lrg425 Dis Engine W Standard Controls Sheet 2 Of 2 Updated 10 98 3120240 JLG Lift 3 35 SECTION 3 TROUBLESHOOTING TERMINAL DESCRIPTION M FUNCTION 18 senar B m m HO
2. 1 2 89 2 39 Spark Arrestor 1 2 89 2 40 Footswitch Adjustment lated as dee ie De ERR UE eds 2 89 2 41 Hydraulic Pump W hayes Pump Drive Coupling 2 89 2 42 Dual Fuel System ies bee ie ie Ite eed nece COMER exi E 2 89 2 43 Preventive Maintenance And Inspection 2 90 2 44 Capacity Indicator e uu el Slee Pal Maoh 2 92 SECTION 3 TROUBLESHOOTING 3 1 Generals oru erie kak Sees Sede iad ee cog 3 1 3 2 Troubleshooting Information 4 3 1 3 3 Hydrauli Circuit Checks gi xr EOD Ee bed ce ER uda alas 3 1 LIST OF FIGURES FIGURE NO TITLE PAGE NO 1 1 Torque Chart eri Ud ROC RC EROSION Ee ed PE CURRERE RO EROR 1 5 1 2 Lubrication Chart Sheet 1 2 1 6 1 2 Lubrication Chart Sheet 2 2 1 1 7 1 3 Serial Number 1 11 2 1 Typical Three Section Boom 2 5 2 2 Boom Positioning and Support Cy
3. 40104001 294 ANTONE nes 1103201 1391 ss Zi wre iras aunssaud 705 AInS8I9 51815 5318918 1 NMO G3H cre X19 1HM 81 ERG Od3dSt3 0 i 1 NOILINOI 1 SS3 ROLCGTHISIG NYO IHM I a 77 7 81 005 tv 77777 a eds 33J9gH98SV 81 G3H NMO OHiNOO EE E RIONSAOO NOISIOSUd NOILINDI yet SI 8 3SY38 NI YONI gt 109435 i 1 910009 3NION3 3 vIdVA ted Bl AMT eee l1N3H334IXO 58 31818 TWNIWYSL JHL YY TIWIS SI ONIMIM VH c 7HOOWHH NV SI NMOHS AMANI 3NION3 GIN 3NION3 3NION3 HOIH HOLIAS SILON 3120240 JLG Lift 2 26 SECTION 2 PROCEDURES High Engine Adjust 8 1 2 Tums C C W Starter Lockout Speed Adjust From Full C W Factory Adjust 2 zi MN el Mid Engine Adjust Directional arrows Q Indicate normal settings Gain Adjust Adjust C C W until overspeed relay drops out amp then 2 1 4 tums C W Part No 1600211 Connections Power Ground ignition Signal ignition Signal Actuator Actuator Starter Relay GND Qverspeed Relay G
4. DIM D DIM E 2 Section CSA App 12 180 1 4 63 1 4 46 1 4 70 3 4 2 Section Dom 12 180 1 4 75 1 4 41 64 3 Section Dom 12 115 5 16 70 3 4 20 1 2 24 1 16 3 Section CSA 12 115 5 16 63 1 4 20 1 2 31 9 16 2 Section CSA App 12 180 1 4 51 7 8 49 12 78 1 8 2 section Dom 12 180 1 4 63 1 4 46 1 4 70 3 4 3 Section Dom 12 115 5 16 56 1 4 23 36 1 16 Figure 2 48 Boom Tape Replacement Chart Capacity Indicator Dial Decal Replacement Dial decal is required to be replaced when illegible or missing A WARNING DECAL LOCATION DIMENSIONS ARE CRITICAL FOR ACCURATE READING OF CAPACITY INDICATOR Indicator Decal Installation 1 Clean and dry wheel surface before installing decal 2 Locate bottom of dial decal 1 16 from 1 8 dia hole on face of gage wheel _ 900 092 009 t T 1 16 POSITION AS SHOWN TO BE READ 1 8 dia hole Ref Figure 2 49 Capacity Indicator Dial 3120240 SECTION 3 TROUBLESHOOTING 3120240 SECTION 3 TROUBLESHOOTING 31 GENERAL This section contains troubleshooting information to be used for locating and correcting most of the operating problems which may develop in the aerial platform If a problem should develop which is not presented in this section or which is not corrected by li
5. Figure 3 4 Wiring Diagram Platform Console W all Hydraulic Controls 3 23 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING 1 WIRING FOR PROP TELESCOPE mE Mc IN nl CIN 77 SIR eI 5 Ta B ere ivi 4 ee Lt ud m n 75558 elis 77 18 90 CABLE TO MAIN TERMINAL 12 4 TO MAIN TERMINA RAY 3 24 Figure 3 5 Wiring Diagram Platform Console Standard Sheet 1 Of 2 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING FOOTSWITCH 1281682 1 Figure 3 6 Wiring Diagram Platform Console Standard Sheet 2 Of 2 3120240 JLG Lift 3 25 SECTION 3 TROUBLESHOOTING 32 32 20 20 29 X 219 1 23 20 22 12 t Hou 1 G 3 26 Figure 3 7 Wiring Diagram Standard Deutz 221511 131912 amp Wisconsin Engine W Standard Controls Sheet 1 Of 2 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING TE Ba xa Al MH 1280727 Figure 3 8 Wiring Diagram Standard Deutz F214511 131912 amp Wisconsin Engine W Standard Controls Sheet 2 Of 2 3120240 JLG Lift 3 27 SECTION 3 TROUBLESHOOTING YELLOW HORIZONTAL HOURMETER VOLTMETER LIMIT SW
6. 2 30 DRIVE BRAKE MICO MACHINES BUILT FROM MAY 1992 TO S N 33476 SEE FIGURE 2 44 Disassembly 1 Remove end cover 2 from housing 21 by removing capscrews 1 A WARNING END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 2000 POUNDS 907 KG THE FOUR CAPSCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE IF A HYDRAULIC PRESS IS AVAILABLE 3000 LBS 1362 KG MAXIMUM THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAP SCREWS 2 Remove case seal 4 from housing 21 then remove bleeder screw 3 from end cover 2 3 Remove piston 7 from end cover 2 4 Remove o ring 5 back up ring 6 o ring 8 and back up ring 9 from piston 7 5 Remove separators 13 from housing 21 6 Remove stack assembly consisting of shaft 11 return plate 14 and friction discs 12 from housing 21 7 Remove dowel pins 20 springs 15 16 and spring retainer 17 from housing 21 8 Remove retaining ring 18 from housing 21 9 Remove shaft by pressing or using a soft mallet on male end of shaft 10 10 Remove retaining ring 22 and bearing 19 from shaft 10 11 Press rotary oil seal 23 from housing 21 Inspection Clean all parts thoroughly Closely inspect all parts for excessive wear cracks and chips Replace parts as necessary Discard seals and o rings Closely inspect bearings and bearing contact sur faces Replace as necessary NOTE Bearings may be re used if after thorough inspec 3120240 tion they are f
7. CUT OUT RELAY HIGH DRIVE Gh HORN RELAYG ENGINE aaa ADJUSTMENT Terem INCREASES Er acere CCW DECREASES rqa RPM BANG BANG 3 sor i IGNITION MODULE ASSEMBLY 3 4 Figure 3 18 Wiring Diagram Standard Ford Dis Engine W Hydraulic Controls Sheet 2 Of 2 JLG Lift 1280991 D 3 37 SECTION 3 TROUBLESHOOTING INTENTIONAL BLANK PAGE 3 38 JLG Lift 3120240 e Corporate Office JLG Industries Inc 1 Drive McConnellsburg PA 17233 9533 USA Phone 717 485 5161 Fax 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit
8. 3 15 SECTION 3 TROUBLESHOOTING TROUBLE Table 3 6 Electrical Assembly Troubleshooting PROBABLE CAUSE REMEDY PLATFORM CONTROLS No power to platform controls Self reset circuit breaker open Contact blockin footswitch malfunctioning Faulty power circuit wiring Selectswitch in wrong position Check footswitch to ensure that both switches are making contact when pedal is depressed Repair or replace footswitch as required Repair replace or adjust contact block as required Check wiring continuity Refer to proper wiring dia gram Place select switch to correct position ENGINE STARTER SYSTEM Starter will not crank Discharged battery or loose battery terminals Starter relay faulty or faulty relay connections Malfunctioning starter solenoid or motor Malfunctioning ignition switch Faulty ignition and or starter circuit wiring Faulty starter lockout system Faulty starter switch Check and charge battery or replace battery as nec essary Clean and secure battery terminals Using a test meter check relay coil terminals for presence of electrical power and for energizing of relay coil Also check relay terminals for correct switching of contacts Replace relay as necessary Replace solenoid or motor in accordance with appli cable manufacturer s manual Using a test meter check ignition switch for correct switchingof contacts Replace switch as necessa
9. 2 6 2 8 Cylinder Checking Procedure 1 2 7 2 9 Cylinder Repalr eR ue Rc Eme tx Xo a es a Ue bond OR RA UR ars 2 9 2 10 Cylinder Removal And Installation 2 III 2 12 2 11 Boom Maintenance er idonee ples taque pe A BU aede RE Tasa E e ER ee UR 2 14 2 12 Tilt Alarm Switch ix ecce ie e Eee ure esee ERE Pre EMT 2 19 2 13 Horizontal High Speed Cutout Switch Adjustment Procedure 2 19 2 14 Governor Checks Addco Adjustment 2 20 2 15 Throttle Checks And Precision Governor Adjustments Addco See Figure 2 6 2 21 2 16 Electric Governor And Adjustments Ford 2 22 2 17 Throttle Checks And Adjustments Deutz F21511 Engine See Figure 2 8 2 29 2 18 Throttle Checks And Adjustments Wisconsin Engine See Figure 2 9 2 33 2 19 Throttle Checks And Adjustments Deutz F3I912 Engine See Figure 2 10 2 35 2 20 Throttle Checks And Adjustments Deutz Engine 31011 See Figure 2 11 2 85 2 21 Pressure Setting 2 38 2 22 Racine Proportional Air Gap 2 58 2 23 SWING Bearing uuu ay aes ee pe eee WING UII UE etd 2 59 2 24 Torque Hub
10. Determine cause and repair or replace 3 10 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY Machine will not travel in forward Hydraulic system oil low Restricted or broken hydraulic line or fitting Control valve not functioning properly Drive motor s notfunctioning properly Circuit breaker open No powerto wheel motor speed switch Two speed valve sticking Counterbalance valve sticking on return side Replenish oil as necessary Clean repair or replace line or fitting Repair or replace valve Repair or replace motor s Determine and correct cause reset circuit breaker See proper wiring diagram Repair or replace valve Adjustreturn counterbalance out turns cycle drive return to original position Machine over speeds when descending a grade Counterbalance valve improperly adjusted or defective Adjustor replace valve Motor turns slowly in the direction of the last command Valve not returning to neutral Function speed switch malfunction Sticking spool due to contamination Check neutral springs Replace function switch Remove end cap and check spool freedom Repair as necessary Motorturns slowly at maximum command Valve spoolis nottraveling far enough due to Worn leaking drive motor s Engine speed too low Low control pressure supply Function speed switch malfunction Amperage too low o
11. bility Make very small adjustments then load and unload engine or pull linkage back slightly and release Usually a good set up is one that makes 1 to 3 small bounces and then steadies down after a large change Too much Gain shows up as a rapid once per second instability most commonly at light loads Too little Gain shows up in large over shoots on start up or large load changes and gen erally sluggish operation Make final adjustment to the High Engine Pot Set machine controls to obtain the mid engine speed Adjust the mid engine pot as needed to obtain the speed desired The start lockout adjustment is factory set If neces sary he starter lockout pot may be adjusted to obtain dropout of the starter as the engine attains running speed Normally this is around 500 RPM The overspeed adjustment is factory set If neces sary it may be readjusted to shut off ignition power at a different engine speed by means of the over speed adjustment pot The overspeed is simply to shut down an over revving engine Overspeed to be set at 4000 4500 RPM ss This is not a function we test for correct settings The High Engine speed must be set before setting the over speed 2 27 SECTION 2 PROCEDURES 10 Re install the back cover on the E 331 Final mount the controller Troubleshooting We will discuss Troubleshooting in two general catego ries Governor won t work Governor works but can t be set
12. 1 CYLINDER SPECIFICATIONS Table 1 3 CYLINDER SPECIFICATIONS DESCRIPTION BORE STROKE ROD DIA Master Level 2 50 15 25 1 25 Slave Level 2 50 15 21 1 25 Lift 6 00 23 50 2 50 Lockout 3 00 4 56 1 25 Oscillating Axle Lock 3 00 4 06 1 25 out 4WD Telescope 3 00 174 18 2 00 2 Section Boom Telescope 3 00 110 31 2 00 3 Section Boom Steer 2WD 3 00 8 06 1 25 Steer 4WD 3 00 9 81 1 50 Extend A Reach Lift 3 00 12 687 2 00 Slave 3 50 7 25 1 75 3120240 1 8 BOOM TAPE Two Section Boom American Standard Red 64 in 162 56 cm Yellow 41 in 104 14 cm Blue 71 50 in 181 61 cm Three Section Boom American Standard Red 24 06 in 61 11 cm Yellow 20 50 in 52 07 cm Blue 70 75 in 179 70 cm Two Section Boom Canadian Standard Red 70 75 in 179 71 cm Yellow 46 24 in 117 47 cm Blue 59 49 in 151 12 cm JLG Lift 1 9 SECTION 1 SPECIFICATIONS 1 9 MAJOR COMPONENTS WEIGHTS TABLE 1 4 COMPONENT WEIGHTS MODEL40H MODEL 40H 6 LBS KG LBS KG Platform 36 x 48 91 4 cm x 122 cm 170 78 170 78 w Control Box Platform 36 x 60 91 4 cm x 152 cm 185 84 185 84 w Control Box Platform 36 x 72 91 4 cm x 182 88 cm 200 90 200 90 w Control Box Platform 36 x 96 91 4 cm x 24
13. Swing Bearing Pinion Gear 9 12 3120240 JLG Lift 2 91 SECTION 2 PROCEDURES 2 44 CAPACITY INDICATOR The capacity indicator is a mechanical gage that indicates the allowable maximum weight in the platform in reference to the angle of the boom A WARNING THE CABLE ADJUSTMENT AND DECAL REPLACEMENT ARE CRITICAL TO INSURE AN ACCURATE READING OF THE CAPAC ITY INDICATOR Capacity Indicator Cable Adjustment 1 Position main boom top plate and platform to be parallel to the floor 2 Adjust the cable to locate the dial in the capacity indicator box so that the indicator line and calibra tion arrows on the nameplate are aligned CAPACITY INDICATOR Q 1000 500 750 4 1000 500 750 O INSTRUCTIONS Capacity Indicator Boom Tape Replacement Replacement of boom tape is required when tape is illegi ble or missing A WARNING THE LOCATION DIMENSIONS AND COLORS ARE CRITICAL FOR AN ACCURATE READING OF THE CAPACITY INDICATOR GAGE Installation Procedure 1 Clean and dry fly boom top surface before installing the tape 2 install tape on center of fly boom to dimensions shown in table 2 92 JLG Lift B TOP END OF PY BOOM TUBE E D gt lt gt r RED YELLO BLUE Y per LET 1 REF CHART DESCRIPTION DIM A DIM B DIM
14. 12 5 x 15 12 ply rating 72 PSI 5 Bar 4 WD Same Tires 14 x 17 5 8 ply rating 45 PSI 3 Bar 4 WD Same Drive Motor Displacement 2 48 inS Rev Drive Hub Ratio 49 29 1 Steer System Tires 12 5 x 15 12 ply rating 72 PSI 5 Bar Toe in adjust for 1 4 in 6 35 mm overall 1 2 Ford LSG423 Deutz F3L912 Wisconsin VG4D with Racine Valves Single Speed Drive Motors First Section to Proportional Valve Drive Lift Swing 14 5 GPM 54 88 LPM Second Section to High Drive 9 5 GPM 35 96 LPM Third Section to Bang Bang valve level Telescope Steer Rotate 9 5 GPM 35 96 LPM Clockwise Rotation Ford LSG423 Deutz F3L912 Wisconsin VG4D with Racine Valves 2 Speed Drive Motors First Section to Proportional Valve Drive Lift Swing 10 8 GPM 40 88 LPM Second Section to High Drive 6 3 GPM 23 85 LPM Third Section to Bang Bang valve level Telescope Steer Rotate 6 3 GPM 23 85 LPM Clockwise Rotation Ford LSG423 Ford LRG423 Deutz F3L912 Deutz F3L1011 Wisconsin VG4D with Vickers Valves 2 Speed Drive Motors First Section to Proportional Valve Drive Lift Swing 15 GPM 56 78 LPM Second Section to High Drive 9 GPM 34 07 LPM Third Section to Bang Bang Valve Level Telescope Steer Rotate 9 GPM 34 07 LPM Clockwise Rotation Auxiliary Power Pump Two section 3 75 GPM 14 19 Ipm each section 12 VDC motor clockwise rotation
15. Barrel End Remote Access 1 Grease Fitting MPG Pressure Gun 150 11 Lift Cylinder Rod End 2 Grease Fittings MPG Pressure Gun 150 12 Master Level Cylinder Rod End 1 Grease Fitting MPG Pressure Gun 150 13 Master Level Cylinder Barrel End 1 Grease Fitting MPG Pressure Gun 150 14 Boom Pivot Bushings 2 Grease Fittings MPG Pressure Gun 150 15 Engine Crankcase Fill Cap Drain Plug EO Refer to end manual 10 150 16 Lockout Cylinder Barrel End 1 Grease Fittings MPG Pressure Gun 100 If Equipped 17 Lockout Cylinder Rod End If Equipped 2 Grease Fittings MPG Pressure Gun 150 18 Oscillating Axle Pivot Pin If Equipped 1 Grease Fitting MPG Pressure Gun 150 19 Steer Oylinder 2 Grease Fittings MPG Pressure Gun 150 20 Steer Spindle 2 Grease Fittings MPG Pressure Gun 150 21 Steer Spindle 4WD If Equipped 4 Grease Fittings MPG Pressure Gun 150 22 Tie Rod Ends 2 Grease Fittings MPG Pressure Gun 150 23 Tie Rods Two Hitch If Equipped 4 Grease Fittings MPG Pressure Gun 150 24 Towing Hitch If Equipped 1 Grease Fitting MPG Pressure Gun 150 25 Wheel Bearings N A MPG Repack 500 26 Wheel Drive Hubs 4WD If Equipped Fill Plug 1 2 Full EPGL SAE 90 50 2 yrs 27 Swing Hub Fill Plug EPGL SAE 90 50 2 yrs 28 Swing Bearing amp Pinion Gear Teeth N A MPG Brush 100 29 Door amp Access Panel Hinges N A SAE 10 Oil Can 30 Hydraulic Filter Element Return N A Replacement Element 40 30
16. Inspect all threaded components for damage includ ing stretching thread deformation or twisting Inspect seal mounting area in hub for burrs or sharp edges Dress applicable surfaces or replace compo nents as necessary Inspect cover for cracks or other damage and o ring sealing area for burrs or sharp edges Dress applicable surfaces or replace cover as necessary 2 67 SECTION 2 PROCEDURES 43 Brake Spindle Assembly Seal Cup Bearing Cone Bearing Cup Bearing Cone Bearing Hub Washer Tongued Lockwasher Locknut Stud Plug Pipe Plug Magnetic Gear Internal Carrier Assembly 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Washer Thrust Roller Needle Spacer Shaft Planet Gear Cluster Pin Roll Gear Ring O Ring Cover Cap Cover Bolt Cap Disconnect Rod Disconnect O Ring O Ring 32 31 32 Ring Retaining 34 35 36 37 38 39 Bolt 41 42 Gasket 44 45 Plug Pipe Shaft Input Spring Spacer Gear Input Spacer Thrust Not Used Washer Thrust Bolt Shoulder Flatwasher Washer Thrust Ring Retaining 2 68 Figure 2 37 Torque Hub 4 WD JLG Lift 3120240 SECTION 2 PROCEDURES Repair 1 Cover Assembly a Remove two bolts 26 securing disconnect cap 27 to cover 25 and remove cap Remove two bolts 26 securing cover cap 25
17. SECTION 1 SPECIFICATIONS 1 1 Capacities Ne CERAM PE DU EN i e eaa tq Eee tus 1 1 1 2 Component 1 ce CIR ERA REG 1 1 1 3 Performance Data sene tpe P RR eve ERR eb Re repe ash a 1 3 1 4 Torque Requirements sol eee e et Rash e ee TR RR p RO RUN Rn 1 3 1 5 IEEE 1 3 1 6 Pressure Settings Gerona ine Luo RES Ni ie the Va eee RA TIAS 1 8 1 7 Cylinder Specifications 1 1 9 1 8 E EET 1 9 1 9 Major Components Weights 1 10 1 10 Critical Stability 5 1 10 1 11 Serial Number Location See Figure 1 4 1 10 SECTION 2 PROCEDURES 2 1 General zc shu Exp bytu enr Eq eS IUS IPS Rees 2 1 2 2 Servicing And Maintenance 2 1 2 8 Lubrication Information 1 4 1 1 2 2 2 4 Cylinders Theory Of Operation 2 2 2 3 2 5 Valves Theory 2 m 2 3 2 6 Boom Chains See Figure 2 4 0 2 4 2 7 Wear Pads tees etos EAT SD oe BR DS EU xe tly BU kas Martine Swa e
18. Secure the spacer if applicable 4 If applicable correctly place a new o ring and back up rings in the inner piston diameter groove 5 Carefully place the piston on the cylinder rod ensur ing that the o ring and back up rings are not dam aged or dislodged 6 Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible 7 Push the piston onto the rod until it abuts the spacer end and install the attaching nut A WARNING WHEN REBUILDING THE LIFT SLAVE LEVEL TELESCOPE STEER SINGLE ROD AND EXTEND A REACH SLAVE AND LIFT CYLINDERS APPLY LOCTITE 242 TO PISTON NUT THEN TIGHTEN BOTH SECURELY SEE TABLE 2 2 FOR TORQUE SPEC IFICATIONS NOTE These cylinders use self locking knurled cup point setscrews which should be discarded and replaced whenever they are removed After torquing piston nut spot drill cylinder rod for set screws 8 If applicable install the setscrew s which secure the piston attaching nut to the diameter groove See Table 2 2 for Torque Specifications 9 Remove the cylinder rod from the holding fixture 3120240 10 Place new o rings and seals in the applicable out side diameter grooves of both the piston and the cyl inder head 11 Position the cylinder barrel in a suitable holding fix ture A IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN INSTALLING THE CYLINDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF C
19. dL Service and Maintenance Manual Model 40H 40H 6 3120240 October 11 2001 ANSI 1509001 IPA REGISTERED COMPANY 015 INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A A GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial plat form It is of utmost importance that maintenance person nel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others or dam age to the equipment A maintenance program must be followed to ensure that the machine is safe to operate A WARNING MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA TION The specific precautions to be observed during mainte nance are inserted at the appropriate point in the manual These precautions are for the most part those that apply when servicing hydraulic and larger machine component parts Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate supp
20. with the boom fully elevated and fully retracted See Figure 2 32a using a magnetic base dial indicator measure and record the distance between the swing bearing and frame See figure 2 34 At the same point with the boom at horizontal and fully extended See Figure 2 32b using a magnetic base dial indicator measure and record the distance between the swing bearing and frame See Figure 2 34 If a difference greater than 057 1 45 mm is deter mined the swing bearing should be replaced If a difference less than 057 1 45 mm is deter mined and any of the following conditions exist the bearing should be removed disassembled and inspected for the following Metal particles in the grease Increased drive power required Noise d Rough rotation If bearing inspection shows no defects reassemble and return to service A IMPORTANT THE SWING BEARING IS ONE OF THE MOST CRITICAL POINTS ON AN AERIAL LIFT IT IS HERE THAT THE STRESSES OF LIFT ING ARE CONCENTRATED AT THE CENTER OF ROTATION BECAUSE OF THIS PROPER MAINTENANCE OF THE SWING BEARING BOLTS IS A MUST FOR SAFE OPERATION Replacement and Devcon Application Procedures on Machines Built Prior to Mid of 1991 1 Removal a From Ground Control station operate the boom adequately to provide access to frame opening or if equipped to rotary cou pling A WARNING NEVER WORK BENEATH THE BOOM WITHOUT FIRST ENGAGING BOOM SAFETY
21. CCW to decrease sensitivity The adjustment range of the Factory range of the pot is about 3 4 of a turn AND OVERTURNING WILL BREAK THE INTERNAL STOPS making further adjustments impossible The Fac tory setting normally will not have to be adjusted JLG Lift 2 25 SECTION 2 PROCEDURES 170 3395 100 170 207 18915 1 3NI9N3 OIN 1 0 NYNL 3NIO9N3 HOIH no NIYI AMOLOVA 30u04 LON 00 NI 5109 P E TW S oI10 ATAIGNY HOLNT lOd IHL 17820 NI SlOd SNUML TTY 59411138 1353949 01 71507 JI 1 0 613634 SNIMGTIOS 3Hl 3SN SHON3ADO NOISIOJ d 8 138344 SINON 7081405 TV WAHL TIM MOA HO SlOd 1 3Hl 39803 LON Od HOLATS ON HLIM 109 772 Ho1n30 HLIM 10 oz 3 nndoW G33d6M3AQ bod HOLIMS LUVIS IHL SNISOTO 3NISN3 HOIH STING O ONILUVLS 1 O M Ol ARALING GAYO JHL SNID 0 8 HO V 150 NO Z HiIA LON TIIA 3NIONG SNION3 HOIH S3 TeVN3 9 Y SNId HLOG NO SNIONG SG TeYN3 8 OW V SNIJ CIN e CIN S3TEVNS 8 SNId 9 NO S310N lt YOLISNNOD Y 5 LE o n I Kshr v LON 00 AV 1323
22. Coil in solenoid is damaged No oil flow or pressure to steer circuit Bent cylinder rod Damaged tie rod Crossover relief valve sticking Cylinder packing defective See proper wiring diagram Repair or replace wiring Replace coil Take pressure reading atsteer valve and adjustas necessary Repair or replace cylinder Replace tie rod Repair crossover relief valve Repair or replace cylinder Machine wanders steering not firm Crossover relief valve settoo low or not functioning properly Steer linkages loose spindle bushings worn Steer wheel toe in not set properly Swivel coupling leaking Reset repair or replace valves as required Tighten linkage replace bushing Adjusttoe in for 1 4 in 6 35 mm overall Repair or replace swivel coupling 3120240 JLG Lift 3 13 SECTION 3 TROUBLESHOOTING TROUBLE Table 3 5 Hydraulic Assembly Troubleshooting PROBABLE CAUSE REMEDY HYDRAULIC SYSTEM GENERAL Hydraulic pump noisy Air entering system through broken line or fitting Suction side Air bubbles in oil Reservoir oil level too low Suction filter dirty Oil filter dirty Restricted suction line Repair or replace line or fitting Replenish oil as necessary Clean or replace filter Replace hydraulic filter Clean repair or replace line Pump cavitation Vacuum in pump due to oil starvation Restricted suction line Re
23. Remove the tongued washer 8 from spindle brake 1 Remove bearing cone 6 from hub 7 Remove hub 7 from spindle brake 1 3120240 SECTION 2 PROCEDURES 15 Using a slide hammer remove seal 2 from the small Cleaning and Inspection end of hub 7 Discard the seal 16 Remove bearing cone 4 from spindle brake 1 17 Using a soft punch and hammer remove bearing cup 5 from the deep end of hub 7 NOTE Be very careful not to strike the counterbore of the hub where the cup is located when using the punch 18 Using a soft punch and hammer remove bearing cup 3 from the shallow end of hub 7 NOTE This cup can be reach by putting the punch into the small access hole in the bottom of the hub s deep end A IMPORTANT WHEN REBUILDING TORQUE HUB REMOVE AND REPLACE ALL O RINGS AND RETAINING RINGS 3120240 JLG Lift 1 Thoroughly clean all parts in an approved cleaning solvent Inspect bearing cups and cones for damage pitting corrosion or excessive wear If necessary replace bearings as a complete set ensuring that they remain covered until use Inspect bearing mounting surfaces on spindle hub input shaft and carrier Replace components as nec essary Inspect all geared components for chipped or bro ken teeth and for excessive or uneven wear pat terns Inspect carrier for damage especially in anti roll pin and planet shaft hole areas Inspect all planet shafts for scoring or other dam age
24. With shoulder side of ring gear 22 facing down place ring gear over into mesh with large gears 20 Ensure punch marks remain in correct location dur ing ring gear installation Place carrier assembly 15 and ring gear 22 together into mesh with internal gear 14 Align the shoulder bolt hole in ring gear 22 marked with an X over one of the shoulder bolt holes in the hub If gears do not mesh easily or carrier assembly does not rotate freely then remove carrier and ring gear and check cluster gear timing Place thrust spacer 38 onto input shaft assembly 32 Install thrust waster 39 into counterbore 15 Use petroleum jelly or grease to hold o ring in place 3120240 SECTION 2 PROCEDURES 24 25 26 27 28 Install cover assembly 24 onto ring gear 22 With oil level check plug in cover located approximately 90 degrees from oil fill plug in hub Locate four shoulder bolts 41 90 degrees apart into counterbored holes in hub marked in step 13 Torque shoulder bolts to 18 25 ft Ibs 25 34 NM Install bolts 40 in remaining holes Torque bolts to 18 25 ft Ibs 25 34 NM Place coupling 48 into spindle and onto input shaft Fill hub one half full of EPGL 90 lubricant before operation 2 26 SWING DRIVE BRAKE MICO MACHINES BUILT PRIOR TO MAY 1992 SEE FIGURE 2 39 Disassembly 1 Separate end cover 4 from housing 26 by removing capscrews 1 and lockwashers 2 A WARNING END COVER I
25. brake assembly release pressure should not exceed 2000 psi 137 Bar unless two additional bolts are used for supplemental clamping 2 85 SECTION 2 PROCEDURES Bolts Cover Bleeder Screw Seal Case O Ring Back Up Ring Piston O Ring Back Up Ring 10 Shaft 11 Stator 12 Rotor 13 Return Plate gt N 14 Springs 15 Springs 16 Spring Guide 17 Retalner Ring 18 Bearing 19 Housing 20 Pins Dowel 21 Retainer Ring 22 Seal Oll 23 O Ring 24 Gasket 25 Plug Plpe Figure 2 46 Swing Brake Mico Machines Built From S N 33476 to Present 3120240 SECTION 2 PROCEDURES 2 34 CONTROLLERS PQ Refer to separate publication 3120351 for complete trou bleshooting wiring and replacement parts OEM Refer to separate publication 3120344 for description troubleshooting wiring and replacement parts VICKERS All Hydraulic Refer to separate publication 3120335 for complete trou bleshooting wiring and replacement parts 2 35 OSCILLATING AXLE BLEEDING PROCEDURE Lockout Cylinder Bleeding Without Holding Valves 1 Make a hydraulic hose using approximately 6 feet of 1 4 in wire braid hose with quick connect fitting on one end and a 1 4 in JIC female fitting on the other Swing the boom over the front of the machine and engage the turntable lock Using ground control raise the boom out of the way Remove the cove
26. clearance 17 Align the attach points of the retraction chains with those of the chain attachment block located at the aft end of the fly section Install the clevis pins and washers through the attaching holes of the chains and block secure the clevis pins by installing new cotter pins 18 Properly position the retraction chain sheave assem blies at the aft end of the mid section ensure all sheave to mounting block attachment holes align Install the sheave pin and secure by installing the s setscrews Position the retraction chains onto the sheaves 19 Align the telescope cylinder base to sheave attach ment points Install the sheave pin through the cylin der base and sheave assembly secure the pin with bolt and washer 20 Secure the sling and lifting device at the telescope cylinder s approximate center of gravity and lift the cylinder to the aft end of the boom assembly A CAUTION WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM IT MAY BE NECESSARY AT SOME POINT TO TURN THE CYLIN DER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED WITHIN THE BOOM CARE MUST BE TAKEN TO MOVE THE CYL INDER SLOWLY INTO POSITION DAMAGE TO COMPONENTS MAY RESULT FROM FORCIBLE IMPACT WITH THESE ASSEM BLIES 21 Position the free end of the extension chain around and over the sheave slowly slide the cylinder into the boom while maintaining tension on the chain This will keep the chain properly seated in the sheave groove through
27. lines 2 The design and manufacturing tolerances of the component working parts are very close therefore even the smallest amount of dirt or foreign matter entering a system can cause wear or damage to the components and generally results in faulty opera tion Every precaution mst be taken to keep hydrau lic oil clean including reserve oil in storage Hydraulic system filters should be checked cleaned and or replaced as necessary at the speci fied intervals required in Figure 1 2 Always examine filters for evidence of metal particles 3 Cloudy oils indicate a high moisture content which permits organic growth resulting in oxidation or cor rosion If this condition occurs the system must be drained flushed and refilled with clean oil 4 It is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Good grade mineral oils with viscosities suited to the ambient temperatures in which the machine is oper ating are recommended for use NOTE Metal particles may appear in the oil or filters of new machines due to the wear in of meshing compo nents 3120240 SECTION 2 PROCEDURES Hydraulic Oil 5 Refer to Table 1 1 for recommendations for viscosity ranges 6 JLG recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity of 10W 30 and a viscosity index of 152 NOTE Start up of hydraulic system with oil tem
28. no load Engine Deutz F3L1011 Oil Capacity 6 34 quarts 6 0 L w Filter 5 8 quarts 5 5 L w O Filter Low RPM 2000 High RPM 3000 Alternator 60 Amp belt drive JLG Lift 1 1 SECTION 1 SPECIFICATIONS Battery 1000 cold cranking Amps 210 min utes reserve capacity 12VDC Fuel Consumption Low RPM 1 9 GPH 7 19 LPH Fuel Consumption High RPM 2 5 GPH 9 46 LPH Horsepower 42 3000 RPM no load Engine Deutz F2L511 Swing System Swing Motor Displacement 3 0 in3 Rev Swing Hub Ratio 69 1 Swing Brake Automatic spring applied hydraulically released disc brakes Hydraulic Pump Oil Capacity 3 5 quarts 3 31 L w Filter 3 0 quarts 2 84 L w o Filter Low RPM 1800 High RPM 2500 Alternator 33 Amp belt drive Battery 1000 cold cranking Amps 210 minutes reserve capacity 12 VDC Fuel Consumption Low RPM 2 03 GPH 7 68 LPH Fuel Consumption High RPM 2 73 GPH 10 34 LPH Horsepower 47 2300 RPM full load Engine Wisconsin VG4D Oil Capacity 5 quarts 4 73 L w Filter 4 5 quarts 4 26 L w o Filter Low RPM 1800 no load High RPM 2400 no load Alternator 35 Amp belt drive Battery 1000 cold cranking Amps 210 minutes reserve capacity 12 VDC Fuel Consumption Low RPM 3 21 GPH 12 15 LPH Fuel Consumption High RPM 3 89 GPH 14 72 LPH Horsepower 37 2500 RPM full load Drive System Tires
29. 1 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 JLG Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska UI Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
30. 2 Bottom Out Basket Level 3 Adjust to 2750 PSI 189 7 Bar Figure 2 29 Solenoid Valve Pressure Settings Machines Built from 1995 To Present Sheet 2 of 2 2 56 JLG Lift 3120240 SECTION 2 PROCEDURES 4640519 2 Extend Adjust 2500 PSI 172 3 Bar Retract Adjust 800 PSI 55 16 Bar Set Extend A Reach Down Set Extend A Reach Up Color Flow Valve To Color Flow Valve To 20 Seconds 20 Seconds 3120240 Figure 2 30 Extend A Reach Valve Pressure and Speed Settings Model 40 6 JLG Lift 2 57 SECTION 2 PROCEDURES 2 22 RACINE PROPORTIONAL AIR GAP ADJUSTMENT NOTE The assembly in Figure 2 31 includes select fit parts in order to maintain a proper air gap These parts must remain as an assembly or if disassembled controlled to insure that these component parts are not intermixed with similar parts the guide tube to the exposed end of the plunger Record this dimension Remove plunger and poppet With poppet removed install plunger and check distance from the end of the guide tube to the exposed end of the plunger Subtract the first dimension from the second dimension this will be the amount of air gap Correct air gap is 018 020 with 018 preferred NOTE In the event that parts do become exchanged or you If air gap is excessive it may be reduced by suspect the air gap to be incorrect Too much air gap using a bra
31. 35 tighten the bolts an torque bolts to 170 ft 165 231NM wet v Remove the lifting equipment w Install the rotary coupling retaining yoke apply a light coating of Loctite Sealant TL277 41 to the attaching bolts and secure the yoke to the rotary coupling with the bolts and lockwasher x Connect the hydraulic lines to the rotary cou pling as tagged prior to removal y At ground control station use boom lift control to lower boom to stowed positionO z Using all applicable safety precautions activate the hydraulic system and functionally check the swing system for proper and safe operation Swing Bearing Torque Values 1 Outer Race 80 ft Ibs 109 NM wet 2 Inner Race 170 ft 15 231 NM wet 3 Swing Bearing Torquing Sequence see Figure 2 35 A WARNING RETORQUE THE INNER AND OUTER SWING BEARING BOLTS AFTER FIRST 200 HOURS OF OPERATION AND EVERY 500 HOURS THEREAFTER 3120240 SECTION 2 PROCEDURES Outer Race Bolts LOAD AXIS Inner Race Bolts FORE TF AFT Figure 2 35 Swing Bearing Torquing Sequence 2 24 TORQUE HUB 2W D SEE FIGURE 2 36 Disassembly 1 Position hub over suitable container and remove drain plugs 7 from unit Allow oil to completely drain then replace drain plugs 2 Remove eight bolts 40 and four shoulder bolts 41 securing cover assembly to hub 8 Remove cover assembly and discard o ring seal 29 3 Lift carrier assembly
32. BE FOLLOWED Changing from gasoline to LP Gas 1 Start the engine from the ground control station 2 Open the hand valve on the LP gas supply tank by turning counterclockwise A CAUTION BE SURE ALL GASOLINE IS EXHAUSTED BEFORE SWITCHING TO LP GAS 3 While the engine is operating place the three posi tion LP Gasoline switch at the ground control station to the center off position Allow the engine to oper ate without load until the engine begins to stum ble from lack of gasoline 4 the engine begins to stumble place the switch to the LPG position allowing the LP fuel to be sent to the fuel regulator Changing from LP Gas to Gasoline 1 1 With engine operating on LP under no load condi tion throw the LP Gasoline switch at the ground control station across to the Gasoline position 2 If engine stumbles because of lack of gasoline place the switch to the LPG position until engine regains smoothness then return the switch to the Gasoline position Repeat as necessary until engine runs smoothly on gasoline 3 Close the hand valve on the LP gas supply tank by turning clockwise JLG Lift 2 89 SECTION 2 PROCEDURES 2 43 PREVENTIVE MAINTENANCE AND INSPECTION SCHEDULE The preventive maintenance and inspection checks are listed and defined in the following table This table is divided into two basic parts the AREA to be inspe
33. Em BLACK Y srant RED 10 i Bec n i 9 B N HIGH ENG S ORANOEON moma La GREENWHT meee RELAY START LOCK BLACK 12 BAT CABLE MINA n I 1 E 1 E sOLENOID cooecoo2oo2otoe OUT RELAY AUX POWER RED BLK RELAY 12 5 4 5 Oj oneen A L z d 1281541 RL C Figure 3 14 Wiring Diagram Standard Deutz F311011 Engine W Hydraulic Controls Sheet 2 Of 2 3120240 JLG Lift 3 33 SECTION 3 TROUBLESHOOTING HORIZ Sw 800 ABOVE HORZ f exse 9 YELLOW 8 19 REEK OAK EL BLK R RN BLK ji ED Y sen 1 7 IH5 510 8 69 zm ie 4 S 2 BLK YEL RED YEL BLUZYEL ORN YEL 5 E im qaad 192205172170 S SPEED CUTOUT 41 2 spEED Rio DRIVE 16 3 CABLE ler se HIGH fe n i DRIVE eic ze E gt lt HIGH 7 RELAY Ri2 5 eooo0coccce YEL BLU 5 ORN RED RED ORN YELLOW
34. Hydraulic Filter Tank Return Bypass Type 10 Microns Nominal Hydraulic Filter On line Racine Valve Only JLG Lift Return Non Bypass Type 3120240 SECTION 1 SPECIFICATIONS 10 Microns Nominal 1 3 PERFORMANCE DATA Travel Speed Machine Stowed Height 2WD 4 5 MPH 7 2 4WD 4 0 MPH 6 4 KM HR Gradeability 2WD 25 or 14 slope hard surface AWD 40 or 22 slope hard surface Turning Radius Model 40H 2WD 7 ft 10 in 2 39 M Model 40H 4WD 7 ft 10 in 2 39 M Machine Stowed Length Model 40H 2WD 25 ft 2 in 7 67 M Model 40H 4WD 25 ft 2 7 67 M Model 40H 6 4WD 26 ft 10 in 8 18 M Machine Width Model 40H 40H 6 2WD 4WD 7 11 in 2 41 M Wheelbase 2WS 2WD 16 ft 6 in 5 1 m 2WS 4WD 16 ft 6 in 5 1 m Boom Speed Lift Up 25 40 Seconds Down 20 30 Seconds Telescope Speed Extend 50 80 Seconds Retract 40 60 Seconds Swing Speed 360 Left 61 92 Seconds Right 61 92 Seconds Boom Elevation 74 above horizontal 22 below horizontal Model 40H 6 74 15 ART above horizontal 22 80 ART below horizontal Machine Weight Model 40H 2WD 11 600 LBS 5 266 KG Model 40H 4WD 12 000 LBS 5 448 KG Model 40H 6 13 350 LBS 6 005 KG 3120240 Model 40H 40H 6 2WD 4WD 92 i
35. Lock Engaged 4 Activate Swing Left Adjust To 1000 PS 68 95 Bar 5 Activate Swing Right Adjust To 1000 PSI 68 95 Bar CHECK POINT FOR MAIN RELIEF Note Lift Up and Drive Operate at System Pres sure ADJUSTMENT FOR MAIN RELIEF DRIVE AND LIFT UP 1 Engine Low RPM 2 Bottom Out Lift Up 3 Adjust To 2800 PSI 193 06 Bar System Pressure Figure 2 12 Racine Proportional Valve Pressure Setting Machines Built Prior To Mid 1987 Sheet 1 of 2 3120240 JLG Lift 2 39 SECTION 2 PROCEDURES A IMPORTANT Take pilot pressure reading before attempting 1 Engine low RPM to make adjustment Do not adjust if pilot pressure is between 250 400 PSI 17 2 31 Bar 2 Connect 12 volt Jumper wire to dump valve solenold 3 Pressure gauge should read between Note 250400 PSI 17 2 The pilot pressure is factory set and normally 4 Shut down system remove cap plug and should not require adjusting Adjust only if you no shim up spring to Increase pressure tice poor or sluggish response to proportional func shorten spring to decrease pressure tlons or loss of auxillary power 5 Install cap plug and repeat steps 1 thru 3 CONNECT 12V JUMPER WIRE PILOT PRESSURE ADJUSTMENT POINT CHECK POINT FOR PILOT PRESSURE Figure 2 13 Racine Proportional Valve Setting Machines Built Prior To Mid 1967 Sheet 2 of 2 2 40 JLG Lift 3120240 SECTION 2 PROCE
36. Loosen the three cover plate screws b Adjust the cover to open the choke plate 1 32 c Readjust for ambient temperature by rotating the cover one 1 mark per 5 F from 70 Rotate CCW lean if warmer than 70 CW rich if colder than 70 If actual temperature is 80 set at 1 32 and rotate two 2 marks CCW lean direction Tighten the three cover plate screws and check for free rotation no sticking or binding of the choke shaft NOTE Springs in the system carburetor return springs acceleration pump springs etc are not usually needed and can cause governing problems b Governor is unstable at light load or no load See Linkage for carburetor engines c Governor experiences sudden momentary spikes toward max at random intervals then recovers 1 Look for loose wiring or momentary shorts in wiring Noise or occasionally missing speed signal d Speed seems to slowly wander 5 15 second periods around at speed particularly at higher loads See item 2a 3 concerning excessive on Governor 3 Governor not tuned or adjusted for engine applica tion The basic adjustment to set sensitivity stability is the Gain pot A good starting point for many engines is full CCW then CW 1 3 turn See Governor adjustment section To increase stability turn CCW If satisfactory governing cannot be achieved with this one adjustment the factory adjustment may be needed Normal starting point for
37. Preventive Maintenance and Inspection 2 91 3 1 Platform Assembly 0 2 3 2 3120240 JLG Lift iii TABLE OF CONTENTS Continued 3 2 3 3 3 4 3 6 Boom Assembly 0 3 3 Turntable Assembly 1 3 7 Chassis Assembly Troubleshooting 3 9 Hydraulic Assembly Troubleshooting 2 3 14 Electrical Assembly Troubleshooting 3 16 INTENTIONAL BLANK PAGE JLG Lift 3120240 SECTION 1 SPECIFICATIONS SECTION 1 SPECIFICATIONS 11 CAPACITIES Fuel Tank 37 Gallons 140 2 L Hydraulic Oil Tank 37 U S Gallons 104 2 L Hydraulic System Including Tank 70 U S Gallons 264 95 L Torque Hub Drive 2 5 Pints 1 18 L Torque Hub Swing 2 0 Pints 1 18 L NOTE Torque Hubs should be one half full of lubricant EPGL 90 Engine Crankcase Ford LSG423 w Filter 5 quarts 4 73 L Engine Crankcase Ford LRG423 w Filter 5 quarts 4 73 L Engine Crankcase Deutz F3L912 w Filter 9 5 quarts 8 99 L Engine Crankcase Deutz F3L1011 w Filter 6 34 quarts 6 0 1 Engine Crankcase Deutz F2L511 w Filter 3 5 quarts Eng
38. Repair or replace valve Repair or replace cylinder Machine hard to steer or steering is erratic Hydraulic system oil low Restricted hydraulic line or fitting Lack of lubrication Restricted crossover relief valve Steer system pressure low Bentlinkage tie rod s or steering hitch Hydraulic pump not functioning properly Steer cylinder not functioning properly Spindle pins tight or need lubrication Replenish oil as necessary Clean repair or replace line or fitting Lubricate as required Refer to Lubrication Chart Clean or replace valve Adjust pressure Repair or replace linkage as required Repair or replace pump Repair or replace cylinder Repair or lubricate spindles 3 12 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY Steering inoperative Circuit breaker open Damaged wiring on control switch or solenoid valve Solenoid valve not functioning properly Control switch not functioning properly Relief valve improperly set or not functioning prop erly Steer cylinder not functioning properly Determine and correct cause reset circuit breaker See proper wiring diagram Repair or replace valve Replace switch Reset repair or replace valves as required Repair or replace cylinder Machine will not steer left or to the right Wiring on control switch is damaged Wiring on solenoid valve damaged
39. Repeat this step two more times A IMPORTANT ONE TANG ON LOCKWASHER 9 MUST LINE UP WITH ONE 21 NOTCH ON LOCKNUT 10 IF ON TANG AND NOTCH ARE NOT ALIGNED APPLY SUFFICIENT INCREASED TORQUE UNTIL THEY ARE NEVER LOOSEN THE LOCKNUT 11 Bend the aligned tang on lockwasher 9 up into the NOTE notch on locknut 10 12 Using acenter punch and hammer stake locknut 10 at four equally spaced points around the locknut 22 and at a distance of 1 8 in from its inside edge 23 Place o ring 23 into cover assembly counterbore 2 70 Lift Mark the four shoulder bolt holes on hub 7 so they can be aligned with the shoulder bolt holes in the ring gear and cover in a later step Place internal gear 14 into hub 7 so that its internal splines mesh with the external splines of the spindle brake 1 Apply oil to internal gear 14 Place thrust washer 39 onto spindle brake 1 so that it rests on the bottom of internal gear 14 With large splined end down place input shaft assembly 32 into spindle brake 1 Place thrust spacer 37 onto input shaft 32 With internal splines facing up place input gear 36 into mesh with input shaft sub assembly 32 Place carrier assembly 15 on a flat surface with large ends of cluster gears 20 face up and positioned as shown in Figure 2 38 Find punch marked tooth on each large gear and locate at 12 o clock straight up from each planet pin Marked tooth will be located just under carrier on upper two gears
40. Step 17 applies to 2 Section Boom Only Using the lifting device carefully pull the cylinder from the boom assembly Steps 18 and 19 apply to 3 Section Boom Only As the cylinder is removed from the boom lay the extension chain on top of the base boom Using another lifting device support the sheave wheel end of the cylinder and remove the cylinder from the boom assembly Step 20 applies to 2 Section Boom Only Using another lifting device support the rod end of the cylinder and remove the cylinder from the boom assembly Carefully lift the cylinder clear of the boom assembly and lower to the ground or suitably supported work area Telescope Cylinder Installation 1 3120240 Using suitable lifting equipment carefully lower the cylinder to the boom assembly Using another lifting device support the sheave wheel or rod end of the cylinder and install the cyl inder into the boom assembly NOTE NOTE 10 NOTE 11 12 13 14 15 16 17 18 NOTE 19 JLG Lift Slide the cylinder into boom sliding the extension chain 8 Section Boom Only in place as the cylinder is moving in Steps 4 5 and 6 apply to 3 Section Boom Only Attach a suitable lifting device to the extension chain adjusting eyebolt Install chain adjust block with four 4 lock washer and bolts to base boom section Install the two 2 extension chain adjusting nuts that attach the eyebolt to the
41. a 3 8 9 53mm rod just fits between choke plate and car buretor body The above procedure outlines the correct choke system adjustment for most conditions Some envi ronments such as high altitude very warm or very cold temperatures may require that the choke cover be set richer or leaner or the amount of putoff may need to be varied somewhat 2 21 SECTION 2 PROCEDURES Carburetor and Governor Adjustment 1 NOTE NOTE 2 22 With the aid of an assistant start the engine at the platform console and allow it to come up to operat ing temperature with air cleaner installed Adjust car buretor idle screw until engine idles at 1000 RPM Shut down engine Steps 2 and 3 are preliminary settings On controller in ground control box turn high engine P1 adjusting screw 25 30 turns CCW then 10 turns CW On controller in ground control box turn gain P2 adjusting screw CCW to the stop then CW until Screw slot is vertical approximately 1 4 turn On controller in ground control box turn droop P3 adjusting screw CCW to the stop then CW until Screw slot is vertical approximately 1 4 turn No fur ther adjustment should be necessary to droop P3 With the aid of an assistant at platform console start the engine and allow to come up to operating tem perature Then have assistant depress footswitch and place engine speed switch to HIGH ENGINE If engine surging occurs at this point tu
42. a good speed signal but their absence proves that there is a problem 5 Incorrect Electrical Hook up If steps 1 4 above have not revealed the problem the governor may have been damaged either in shipping or during hook up and test Governor reacts but can t be set up to give proper per formance This kind of trouble usually falls into three main catego ries 1 Actual Governor malfunction 2 Governor installation problems and improper adjust ment 3 Governor not tuned or adjusted for engine applica tion NOTE Assure the engine is operating properly by running engine manually The Governor will not control any poor running engine 1 Actual Governor Malfunction The Governor was engine tested for proper operation just prior to being shipped Unless damaged in shipment or by improper handing it should be serviceable To check for proper operation proceed as follows a Once again disconnect fuel system linkage from Governor output arm and control engine manually b Start engine hold at a low speed Governor arm should move to full fuel position c Increase engine speed carefully At some engine speed Governor arm should move to low fuel position d By carefully varying engine speed you should be able to cause the Governor arm to pause momentarily near the middle of its travel This engine speed is the speed for which the Gover nor is adjusted If grossly incorrect reset High Engine P
43. are found to be in good condition Assembly NOTE Lubricate all seals o rings cylinder of power plate and piston with clean hydraulic oil prior to assembly 1 Use the reverse of the disassembly procedure with the following notes and additions 2 Worn o rings and damaged or worn teflon back up rings must be replaced prior to assembly 3 Ifreplacement of bleeder 19 is necessary install 1 2 to 3 4 turns beyond finger tight 4 Assemble piston 14 into power plate 20 using a shop press being careful not to damage the o rings or teflon back up rings Visually align the center of the cutouts in the piston with the torque pin 9 holes in the power plate 5 Rotating discs 12 must be clean and dry with no presence of oil on any lining material or mating sur face or the stationary discs 13 6 Install bolts 23 Tighten sequentially one turn at a time until power plate 20 is properly seated Torque to 50 60 ft Ibs 68 81 NM JLG Lift 2 77 SECTION 2 PROCEDURES 1 Snap Ring 13 2 Snap Ring 14 3 Bearing 15 4 Housing 16 5 O Ring 17 6 Spring 18 7 Spring 19 8 Shaft 20 9 Pins 21 10 Primary Disc 22 11 Springs 23 12 Rotating Discs Stationary Discs Piston Back Up Ring O Ring Back Up Ring O Ring Bleeder Power Plate Not Used Lockwasher Bolts Figure 2 42 Drive Brake machines Built Prior to May 1992 2 78 JLG Lift 3120240 SECTION 2 PROCEDURES
44. at a rate of 6 8 drops per minute or more the following cylinder repairs must be made If the retract port is leaking the piston seals are defective and must be replaced If the extend port is leaking the counterbalance valve is defective and must be replaced If no repairs are necessary or when repairs have been made carefully reconnect hydraulic hoses to the appropriate ports 2 7 SECTION 2 PROCEDURES FULLY RETRACTED AT HORIZONTAL 2 8 Figure 2 2 Boom Positioning and Support Cylinder Repair JLG Lift 3120240 SECTION 2 PROCEDURES 5 If used remove boom prop from beneath boom activate hydraulic system and run cylinder through one complete cycle to check for leaks Cylinders With Dual Counterbalance Valves Platform Slave Level Cylinder Lockout Cylinder and Extend A Reach Level Cylinder A IMPORTANT OPERATE ALL FUNCTIONS FROM GROUND CONTROL STATION ONLY 1 Using all applicable safety precautions activate hydraulic system 2 When working on the platform slave level cylinder stroke platform slave level cylinder forward until plat form sits at a 45 angle 3 Shut down hydraulic system and allow machine to sit for 10 15 minutes If machine is equipped with a bang bang or proportional control valves turn IGNI TION SWITCH to ON move control switch or lever for applicable cylinder in each direction then turn IGNITION SWITCH to OFF If machine is equipped
45. cause Chain side wear noticeable when pin heads and outside plates show a definite wear pattern is caused by misalignment of the sheave chain anchors and must be corrected promptly Do not repair chains if a section of chain is damaged replace the entire chain set EC Example 595 of H H for a 1 chain 950 Maximum wear 5 of 950 047 a film of oil on all chain surfaces will inhibit rusting and corrosion This is important as corrosion of highly stressed hardened steel chain compo nents can cause a major reduction in the load capacity of leaf chain and result in link plate cracking NOTE The need for lubrication can be determined by the presence of rust on the exposed portions of chain Rust and Corrosion Rust and corrosion will cause a major reduction in the load carrying capacity of the chain because these are primary reasons for side plate cracking The initial lubrica tion at the factory is applied in a hot dip tank to assure full penetration into the joint Do not steam clean or degrease this lubricant on chains A grade of SAE 30 or 40 weight non detergent motor oil should be used as a supplemental lubri cant and a film of this oil should be constantly maintained on the surfaces and internal joints At time of chain installation factory Lube must be supplemented by a maintenance program to pro vide a film of oil on the chains at all times If chains are corroded they must be inspected especiall
46. centerline of eye Dimension should be 1 5 8 inch 3 Manually move the governor throttle lever to maxi 2 mum high speed position The Addco actuator must be disconnected to accomplish this The car buretor throttle lever should have 1 32 to 1 16 inch travel remaining to stop The governor high speed stop screw was removed at the factory 1 With the throttle rod Addco actuator discon nected from governor advance governor arm to high speed position This should advance governor throttle lever to maximum wide open position Verify wide open position of lever by checking governor spring for tension Reconnect throttle rod From ground control start engine Allow engine to come up to normal operating temperature Advance governor arm to wide open position Set high engine speed at 2400 RPM by making adjustments at throt tle rod Return engine to low speed 15 8 4 SPRING SPREADER ADJUSTMENT THROTTLE ROD TO CARB Figure 2 4 Governor Adjustment Ford with Addco 3 If the engine hunts or surges in the maximum speed 5 no load condition decrease engine speed until surging stops Increase speed slowly to 2325 RPM Slowly turn governor surge screw clockwise until no load engine speed increases to 2400 RPM Lock surge screw in position Shut off engine NOTE Do not turn surge screw in any further than neces sary or governor performance will be affected 4 From basket for
47. from idle to high engine Mid engine This adjustment is made by turning the 1 8 brass screw clockwise CW to increase speed and counterclockwise CCW to decrease speed The adjustment range of the Mid engine pot is about 25 turns each turn will change engine speed by about 100 to 200 RPMS THE pot is pro tected by an slip clutch at each end and will not be harmed by moderate over adjustment However the gov ernor will not function when the pot is past full travel If you suspect that you have over adjusted the Mid engine pot or have lost track of where you are turn the pot 25 turns out CCW then turn in CW 15 turns This will get you back into the range you should be in Make all adjust ments before setting the mid engine Start lockout This adjustment is made by turning the 1 8 brass screw clockwise CW to increase speed and counterclockwise CCW to decrease speed The adjustment range of the Start lockout pot is about 25 turns each turn will change engine speed by about 100 to 200 RPMS This pot is pro tected by a slip clutch at each end and will not be harmed by moderate over adjustment However the governor will not function when the pot is past full travel If you suspect that you may have over adjusted the Start lockout pot or have lost track of where you are turn the pot to 25 to 30 turns in CW Then turn out CCW 8 1 2 turns This will get you back into the range you should be in Start lock out should n
48. in 3 Adjust to 2500 PSI 172 4 Bar STEER LEFT AND STEER RIGHT ADJUSTMENT 1 Engine Low RPM 2 Bottom out steer left adjust to 1500 PSI 103 4 Bar 3 Bottom out steer right adjust to 1500 PSI 103 4 Bar Figure 2 22 Solenoid Valve Pressure Settings Machines Built Prior To 1992 With Steering Wheel 3120240 JLG Lift 2 49 SECTION 2 PROCEDURES Adjust Flow To 2 2 1 4 4640151 PRIORITY FLOW CONTROL VALVE Adjust To 2500 PSI 172 4 Bar Disconnect and install Flow Meter ROTATOR VALVE a TO SET FLOW Install a flow gauge inline at rotate valve With the aid of an assistant make adjustments at the priority flow control valve for 2 2 1 4 GPM b TO SET PRESSURE Install pressure gauge at quick disconnect on dump valve With the aid of an assistant make adjust ments at rotator valve to 2500 PSI 172 4 Bar Set with engine at low RPM and bottom out rotate left or right Install Pressure Gauge 4640360 DUMP VALVE Tele and Out Adjustments At Opposing Ends Block Port 4640447 When Adjusting 4 Main Relief Pilot operated e Check Adjust To 2500 PSI 172 4 Bar Install Pressure For Main Relief Gauge 2 STACK VALVE TO SET MAIN RELIEF PRESSURE Install pressure gauge at quick disconnect on 2 stack valve Disconnect level hose plug hose and block on valve Make adjustments at 2 stack to 2500 P
49. mid section remove the wear pads from the top sides and bottom of the mid section Remove bolts and lock washers which secure the chain block weldment to the aft end of the fly sec tion Remove the cotter pins from the clevis pins which secure the extension chain and retraction chains to the block remove the clevis pin washers and chains from the block Using suitable lifting equipment remove the fly sec tion from the mid section place the fly section on a suitable trestle Remove the bolts which secure the wear pads to the aft ends of the fly and mid sections remove the wear pads from the boom sections Inspection NOTE 1 2 16 Steps 1 thru 4 apply to 3 Section Boom Only Inspect all sheaves extend chains retract chains and telescope cylinder for excessive groove wear burrs or other damage Replace sheaves as neces sary Inspect extend chain and retract chain sheave bear ings for wear scoring or other damage and for ovality Replace bearings as necessary ensuring they are installed flush with sheave surface NOTE 10 11 NOTE 12 13 14 Inspect extend chain and retract chain sheave pins for scoring tapering ovality and evidence of correct lubrication Replace pins as necessary Inspect telescope cylinder sheave pin for tapering scoring ovality and evidence of correct lubrication Replace pin as necessary Inspect boom pivot pin for wear scoring or other damage
50. not functioning properly Electrical failure Orifice plugged Clean repair or replace line or fitting Repair or replace cylinder See proper wiring diagram Clean orifice Platform Will Not Adjust Down To Level See Platform will not adjust up to level 3 2 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING Table 3 2 Boom Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY BOOM ELEVATION SYSTEM No response to control Lift control inoperative Repair or replace control lever Lift cylinder holding valve inoperative Repair or replace holding valve Dump valve bypass not operating Determine cause and repair or replace valve Electrical malfunction See wiring diagram Hydraulic system oil low Replenish oil as necessary Restricted or broken supply line on valve bank or Clean or replace line hydraulic pump Control valve not functioning properly Repair or replace valve Lift cylinder not functioning properly Repair or replace cylinder Hydraulic pump not functioning properly Repair or replace pump Boom will not raise Load capacity exceeded personnel or equipment Reduce load Refer to capacity placard onplatform Hydraulic system oil low Replenish oil as necessary Electrical failure to valves See wiring diagram Restricted or broken supply line on fitting Clean repair or replace line or fitting Control valve not functioning properly Repair or repla
51. pins 20 until disc rests on springs 15 16 A IMPORTANT DISC 15 19 AND FRICTION DISCS 17 SHOULD REMAIN DRY DUR ING INSTALLATION NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES PLACE A NEW FRICTION DISC 12 ON SHAFT 10 UNTIL IT CONTACTS RETURN PLATE 14 7 Place a new friction disc 12 on shaft 10 until it con tacts return plate 14 8 Add additional new discs 11 and new friction discs 12 as required to complete assembly 9 Insert separators 13 in holes of return plate 14 10 Install new o ring 5 new back up ring 6 new o ring 8 and new back up ring 9 on piston 7 Note order of o rings and back up rings Insert piston 7 into end cover 2 being careful not to shear o rings or back up rings 11 Install new case seal 4 in housing 21 then install bleeder screw 3 in end cover 2 12 Position end cover 2 on housing 21 aligning dowel pins 20 with holes in end cover 13 Install capscrews 1 and tighten evenly to draw end cover 2 to housing 21 Torque capscrews to 55 ft Ibs 75 NM NOTE f available a hydraulic press will simplify installation of end cover on housing Clamp cover in position while tightening the capscrews 14 If hydrostatic bench testing is performed on the brake assembly release pressure should not exceed 2000 psi 137 Bar unless two additional bolts are used for supplemental clamping JLG Lift 2 81 SECTION 2 PROCEDURES Bolts Cover 10 Sha
52. retracted shut down engine and carefully disconnect hydraulic hose from cylinder extend port Activate engine and retract cylinder Check extend port for leakage If extend port leakage is less than 6 8 drops per minute carefully reconnect hose to extend port then activate cylinder through one complete cycle and check for leaks If leakage continues at a rate of 6 8 drops per minute or more cylinder repairs must be made Lift Cylinder Telescope Cylinder and Extend A Reach Lift Cylinder A IMPORTANT OPERATE ALL FUNCTIONS FROM GROUND CONTROLS 1 Using all applicable safety precautions activate hydraulic system A WARNING WHEN WORKING ON THE LIFT CYLINDER RAISE THE BOOM TO HORIZONTAL AND PLACE A BOOM PROP APPROXIMATELY 1 INCH 2 50 CM BELOW THE BOOM DO NOT WORK ON THE CYL INDER WITHOUT A SUITABLE PROP IN PLACE REFER TO FIG URE 2 2 2 JLG Lift After completing the above shut down hydraulic system and allow machine to sit for 10 15 minutes Turn IGNITION SWITCH to ON move control switch or lever for applicable cylinder in each direction then turn IGNITION SWITCH to OFF This is done to relieve pressure in the hydraulic lines Carefully remove hydraulic hoses from appropriate cylinder port block There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should not be any further leakage from the ports If leakage continues
53. rotary oil seal 22 into housing 19 Note direction of seal Install new bearing 18 and retaining ring 21 on shaft 10 Insert shaft assembly and retaining ring 17 in hous ing 19 Insert dowel pins 20 spring retainer 16 and springs 14 15 in housing 19 Position new large diameter return plate 13 in hous ing with tab guided by dowel pins 20 until disc rests on springs 14 15 A IMPORTANT 12 AND RETURN PLATE 13 SHOULD REMAIN DRY DUR ING INSTALLATION NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES T 10 11 12 NOTE 13 JLG Lift Place a new friction disc 12 on shaft 10 until it con tacts return plate 13 Add additional new discs 11 and new friction discs 12 as required to complete assembly Install new o ring 5 new back up ring 6 new o ring 8 and new back up ring 9 on piston 7 Note order of o rings and back up rings Insert piston 7 into end cover 2 being careful not to shear o rings or back up rings Install new case seal 4 in housing 19 then install bleeder screw 3 in end cover 2 Position end cover 2 on housing 19 aligning dowel pins 20 with holes in end cover Install capscrews 1 and tighten evenly to draw end cover 2 to housing 19 Torque capscrews to 55 ft Ibs 75 NM If available a hydraulic press will simplify installation of end cover on housing Clamp cover in position while tightening the capscrews If hydrostatic bench testing is performed on the
54. the cartridge any time the system oil is changed 10 While the unit is shut down a good preventive main tenance measure is to make a thorough inspection of all hydraulic components lines fittings etc as well as a functional check of each system before placing the machine back in service Lubrication Specifications 3120240 Specified lubricants as recommended by the component manufacturers are always the best choice however multi purpose greases usually have the qualities which meet a variety of single purpose grease requirements Should any question arise regarding the use of greases in maintenance stock consult your local supplier for evalua tion Refer to Table 1 2 for an explanation of the lubricant key designations appearing in the Lubrication Chart 2 4 CYLINDERS THEORY OF OPERATION Systems Incorporating Double Acting Cylinders Cylinders are of the double acting type Systems incorpo rating double acting cylinders are as follows Lift Tele scope Platform Leveling Steer and Lockout A double acting cylinder is one that requires oil flow to operate the cylinder rod in both directions Directing oil by actuating the corresponding control valve to the piston side of the cylinder forces the piston to travel toward the rod end of the barrel extending the cylinder rod piston attached to rod When the oil flow is stopped movement of rod will stop By directing oil to the rod side of the cylinde
55. this adjustment is fully CCW then CW 1 4 turn Before chang ing this pot mark the original position NOTE If problems occurs with the Governor overshooting when a large load is released from the engine such 2 17 THROTTLE CHECKS AND ADJUSTMENTS DEUTZ F2L511 ENGINE SEE FIGURE 2 8 NOTE Never run fuel tank dry Diesel engines cannot be restarted after running out of fuel until fuel system has been air vented or bled of air See Deutz Instruction Manual for procedure Disconnect actuator cable from throttle lever With the aid of an assistant start the engine and allow it to come up to operating temperature Adjust throttle lever stop until engine runs at 1800 RPM Shut down engine Reattach actuator cable to throttle lever making sure that low engine setting remains the same If necessary adjust slide pin to contact low engine limit switch at 1800 RPM Shut down engine With the aid of an assistant start engine from bas ket and allow to come up to operating tempera ture Disconnect proportional dump valve wire Activate footswitch Turn on HIGH ENGINE switch Hold drive controller in full drive position Adjust slide pin to contact high engine limit switch at 3000 RPM Shut off all switches and controllers Reconnect proportional dump valve wire as driving up a hill and stopping There is usually NOTE Actuator cable travel must stop slightly before lever one of two things a Gain adjustment is to far
56. to cover and remove cap Remove disconnect rod 28 from cap and remove o rings 29 30 from cover cap Discard o rings f necessary remove pipe plug 31 from cover Clean and inspect parts in accordance with paragraph Cleaning and Inspection Replace parts as necessary If removed screw pipe into cover Slip o ring 30 over cover cap and against face Place o ring 29 into cover cap internal groove Disconnect rod may be used to push o ring into groove Place cover cap into cover with large hole located over pipe plug Secure cover cap to cover with two bolts Torque bolts to 70 80 in Ibs 7 9 9 0 NM Place disconnect cap over cover cap with nipple facing out and secure with two bolts Torque bolts to 70 80 in Ibs 7 9 9 0 NM Turn cover over and push disconnect rod into cover cap Rod will be held in place by friction from o ring 2 Carrier Assembly a 3120240 Drive anti roll pin 21 into planet 19 using a suit able punch Using a suitable press press planet shaft from carrier 15 After planet shaft is removed drive anti roll pin from shaft Remove cluster gear 20 and thrust washers 16 from carriers Remove sixteen needle rollers 17 from cluster gear bore Remove spacer 18 from cluster gear bore and remove second set of sixteen needle rollers 17 Repeat steps a through e for remaining two clus ter gears Clean and inspect all parts in accordance with paragraph Cleaning an
57. too steep a grade Grade too steep Drive wheel tire treads worn smooth Drive brakes dragging System pressure too low Drive hub s defective Engine RPM not set Counterbalance valve defective Accessory valve not adjusted properly Low amperage on controller Remove machine from grade and checkthat drive system operates correctly See Caution Placard on platform for specified grades and sideslips Replace tires as necessary and inflate to specified pressure Re adjust pressure Re adjust pressure Repair or replace hub Correctly set engine RPM Replace counterbalance valve Correctly adjust accessory valve Correctly adjust controller DRIVE SYSTEM No response to control Hydraulic system oil low Hydraulic pump not functioning properly Restricted or broken pump supply line Restricted or broken line on valve bank or rotary coupling Drive hub s disconnected Rotary coupling leaking internally Seal s worn Drive motor s not functioning properly Airin wheel brake circuit Damaged wiring on control switch Control switch notfunctioning properly Brake s not releasing Replenish oil as necessary Repair or replace pump Clean repair or replace line Clean repair or replace line Reconnect disconnect cap on hub Repair or replace coupling Repair or replace motor s Bleed circuit determine and correct cause Repair or replace wiring Replace switch
58. wheels securely if not on flat level surface 2 Disconnect both drive hubs by inverting disconnect caps in center of hubs 3 If equipped move steer tow selector valve to float tow position by pulling valve knob out To Engage Drive Motors and Brakes Normal Operation 1 equipped move steer tow valve to steer position by pushing valve knob in 2 Connect both drive hubs by inverting disconnect cap in center of hub 3 Remove chocks from wheels as required 2 39 SPARK ARRESTOR MUFFLERS The multiple discs on these mufflers will require frequent cleaning if used with oily or sooty exhaust diesel or on malfunctioning engines as evidenced by visible exhaust 2 40 FOOTSWITCH ADJUSTMENT Adjust so that functions will operate when pedal is at cen ter of travel If switch operates within last 1 4 in 6 35 mm of travel top or bottom it should be adjusted 2 41 HYDRAULIC PUMP W HAYES PUMP DRIVE COUPLING LUBRICATION TO INSURE PROPER OPERATION AND LONG SERVICE LIFE FOR THE HAYES PUMP COUPLING IT IS NECESSARY TO LUBRICATE THE SPLINES OF THE COUPLING ANY TIME THE COUPLING IS DISASSEMBLED OR REPLACED LUBRICATE THE SPLINES WITH TEXACO CODE 1912 PUMP COUPLING GREASE ONLY NO OTHER LUBRICANT IS RECOMMENDED 3120240 2 42 DUAL FUEL SYSTEM A CAUTION IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST
59. work bench or other suitable device 19 Plug the retract port and supply hydraulic power to the extend port 20 Open the bleeder port plug TP venting all trapped air to atmosphere Retighten the bleeder port plug Disconnect the hydraulic power source and remove plug from retract port JLG Lift 2 11 SECTION 2 PROCEDURES 21 An alternative to steps 18 through 20 is to posi tion the barrel horizontally in a suitable holding device attach a hydraulic power source to both extend and retract ports while supporting the cylin der rod cycle the cylinder a minimum of 5 times with the bleeder port unplugged venting all trapped air to atmosphere A suitable hose may be attached to the bleeder port with the end in a container suitable to contain the hydraulic fluid After all air is vented remove all attached hoses and install the bleeder port plug Also plug the extend and retract ports until cylinder is installed in boom Table 2 2 Cylinder Piston Nut Torque Specification Table 2 3 Holding Valve Torque Specifications Description Torque Value SUN 7 8 HEX M20 X 1 5 THDS 30 35 ft Ibs 41 48 NM SUN 1 1 8 HEX 1 14 UNS THDS 45 50 ft Ibs 61 68 NM SUN 1 1 4 HEX M36 X 2 THDS 150 160 ft Ibs 204 217 NM RACINE 1 1 8 1 1 16 12 50 55 ft Ibs THDS 68 75 NM RACINE 1 3 8 HEX 1 3 16 12 75 80 ft Ibs THDS 102 109 NM RACINE 1 7 8
60. 0 31 Hydraulic Filter Element Inline N A Replacement Element 40 300 32 Hydraulic Fluid Oil Fill Plug 1 2 Full HO 10 2 yrs 33 E A R Pivot If Equipped 2 Grease Fittings MPG Pressure Gun 150 34 E A R Lift Cylinder Barrel End If Equipped 1 Grease Fitting MPG Pressure Gun 150 35 E A R Link Boom End If Equipped 2 Grease Fittings MPG Pressure Gun 150 36 E A R Lift Cylinder Rod End If Equipped 1 Grease Fitting MPG Pressure Gun 150 37 E A R Slave Cylinder Pivot Points 2 Grease Fittings MPG Pressure Gun 150 If Equipped 38 E A R Slave Cylinder Rod End 1 Grease Fitting MPG Pressure Gun 150 If Equipped 39 E A R Link Platform End If Equipped 1 Grease Fitting MPG Pressure Gun 150 40 E A R Platform Pivot If Equipped 1 Grease Fitting MPG Pressure Gun 150 Check oil level after every 50 hours of operation Change oil after every 2 years 1200 hrs of operation Check oil level after every 10 hours of operation Change oil after every 3 months 150 hrs of operation Replace filter element after first 40 hours of operation then after every 6 months 300 hrs of operation thereafter Check oil level after every 10 hours of operation Change oil after every 2 years 1200 hrs of operation t will be necessary to swing the boom over side of frame and remove the frame shield to gain access to the grease fitting NOTE Lubrication intervals are based on machine operations unde
61. 06 96 80 06 021 00 OOL 0 S9 06 000 6650 ogoro 06 OL 0 96 08 Ol 05 44 S8 8 SS 4 056 6iviO e SL 028 _ 06 _ 02 09 08 000 09 05 07 SS 0 190 06 OL osgo 08 so 55 0 0956 S Sv OS 0089 lt 90 0 p 9 2 06 08 8 5 9 06 006 9 4 Gc 9 0098 8 800 2 22 Sy 00 06 0 5 SP 000 S 8 ez oe 0 5 00 9 IZ 0056 0585 5 0 Sz 0029 8 Lh vi 6 0022 08500 1 0 72 52 ozs 06 72 _ Sc 049 60 9 L 1L 0 6 0500 8 9Ws v ores 5 00 8 08 Sel 98 00 062 97900 8 osie 09 801 092 SOL S 96 0202 81600 Is 89 9 S 000200 oso ZE S 09 os amp 0 05 100 y 0 amp ow LE 0 0 9100 opopo 9E OX e Ot 006 O0vi00 z 8 S 026 9 09 910100 OF 9 9 085 606000 c _ 009 7 6 002 199000 22 0 y T T 6 a os 9 8 086 70900 0 0 NES im x 1901 H91Vd 9 51108 8 avs SLNN Z 91108 IVS 53895 dV 31V1dN KINO 51108 d31V 1d 9NIZ 804 SANIWA 3120240 SECTION 1 SPECIFICATIONS 33 36 EXTEND A REACH OPTION
62. 120240 SECTION 3 TROUBLESHOOTING 3120240 INTENTIONAL BLANK PAGE JLG Lift 3 19 SECTION 3 TROUBLESHOOTING HOLIMS ALSAVS HLIM 031 19915 S IWNINWS3I HOLIMS a 3078 OWE 034 oe mera folie Ao T33A HOLIMS 122135 16 jeje dG H LIMS 123135 7303 4389 9 l NW AIV H LIMS 18 1 15 RUP OD UU 1281738 Figure 3 1 Wiring Diagram Dual Fuel Ford Or Wisconsin 3120240 JLG Lift 3 20 SECTION 3 TROUBLESHOOTING BO1YN531 V MO1vIS 4931692 D NO 1815 WNIMH3i 13 2 88 OHIINDOM 31815 7W INH31 JO wO1108 NO 8 J TW1SNI 310N 5 9 8 6854 64 ANTY 18 15 NISN3 Av 38 3NION3 5 5 311Hd3 Od XOG NIV Figure 3 2 Wiring Diagram 110v Generator Ford 3 21 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING 49311693 E 3 22 Figure 3 3 Wiring Diagram 110v Generator Deutz JLG Lift 3120240 SECTION 3 TROUBLESHOOTING 31 WIL NO OF OL 99 NOUS JWA HIJAN MOT13A Orrid TIOH 8Z008S TTVISNI ONY HOLS HOLIMS 31V 10H ONV V3sLLS 3AON3U T33H A ONIHSSLIS S3NIHOYW 31ON e 1280994 D
63. 2 Platform Gate 1 4 12 3 Platform Rotator 5 11 4 Footswitch 1 11 5 Controllers 1 11 6 _ Switches 1 11 7 Placardsand Decals 1 2 8 Control Tags 1 2 9 Valves 1 11 5 6 10 Carrier Hoses and Tubing 1 4 8 11 Hydraulic Hoses and Tubing 1 5 12 Chains 8 13 Chain Adjusters 9 14 Sheaves 12 8 15 Pins 8 16 _ Bushings 8 17 Wear Pads 8 18 Oylinders 1 5 6 13 TURNTABLE 1 Engine Oil See MFG Manual 3 5 2 Battery 3 5 3 Radiator If Equipped 3 5 4 AirCleaner 1 14 5 Exhaust System 1 1 5 6 SparkArrester 1 1 5 17 7 Engine Mounts 1 8 Ground Controls 1 2 11 9 Main Hydraulic Pump 1 5 10 Auxiliary Power Pump 1 5 11 Valves 1 11 5 12 Hydraulic Filters 14 5 13 Hydraulic Hoses and tubing 1 5 14 Hydraulic Oil Tank 3 5 4 15 Breather Hydraulic Tank 6 14 16 Fuel Tank 3 5 4 17 Cylinders 1 5 6 13 4 18 Hood Doors amp Sields 1 19 Turntable Locking Pin 1 7 20 Horizontal Limit Switch 1 7 21 OilCoupling 5 22 Placards and Decals 1 2 23 Swing Bearing 1 9 12 24 Swing Brake 1 5 6 8 25 Swing Hub 3 9 CHASSIS 1 Wheeland Tires Assembly 1 8 9 15 2 Drive Motors 1 5 6 3 _ Drive Torque Hubs 1 5 6 3 4 Drive Brakes 1 5 6 5 Steer Cylinders 1 1 5 6 13 6 Steer Components 1 4 6 8 7 LockoutCell If Equipped 1 5 13 8 8 FrontAxle Pin If Equipped 1 8 9 Hydraulic Hoses 1 10 Placardsand Decals 1 2 11 Wheel Bearings 8 12
64. 2w d See Figure 2 36 2 63 2 25 Torque Hub 4wd See Figure 2 37 4 2 66 2 26 Swing Drive Brake Mico Machines Built Prior 1992 See Figure 2 39 2 71 2 27 Drive Brake Mico Machines Built Prior To May 1992 See Figure 2 40 2 72 2 28 Swing Drive Brake Ausco Machines Built Prior To May 1992 See Figure 2 41 2 75 2 29 Drive Brake Ausco Machines Built Prior To May 1992 See Figure 2 43 2 77 2 30 Drive Brake Mico Machines Built From May 1992 To S n 33476 See Figure 2 44 2 79 2 31 Swing Brake Mico Machines Built From May 1992 To S n 33476 See Figure 2 45 2 81 3120240 JLG Lift i TABLE OF CONTENTS Continued 2 32 Drive Brake Mico Machines Built From S n 33476 To Present See Figure 2 46 2 83 2 33 Swing Brake Mico Machines Built From S n 33476 To Present See Figure 2 46 2 85 2 34 Controllers 5 zzi eet ines vg dee eaten Sabe ed uique a P 2 87 2 35 Oscillating Axle Bleeding 2 87 2 36 Oscillating Axle Lockout 0 5 2 88 2 37 Basket Rotator Brake See Figure 2 48 2 89 2 38 Free Wheeling Option
65. 3 84 cm 240 109 w Control Box 2 Section Boom Includes Boom Lift 1795 814 2165 982 Cylinder Rotator and Support 3 Section Boom Includes Boom Lift 2275 1032 2645 1200 Cylinder Rotator and Support Turntable Complete 4687 2126 5925 2688 Frame Complete Includes Pneumatic Tires and Wheels 5020 2277 5020 2277 2WD Frame Complete Includes Pneumatic Tires and Wheels 5420 2458 5420 2458 4WD Complete Machine 2WD 11 600 5 266 13 350 6 055 Complete Machine 4WD 12 000 5 448 13 750 6 237 1 10 CRITICAL STABILITY WEIGHTS TABLE 1 5 CRITICAL STABILITY WEIGHTS MODEL 40H MODEL 40H 6 LBS KG LBS KG Counterweight 1 5 1 910 412 8 2490 1129 5 If Removable 2 1 1075 487 6 2690 1220 2 Tires sIZE 12 5L 15 12 5L 15 ballasted Only Weight 305 138 4 305 138 4 Engine Ford 525 238 1 525 238 1 Deutz 600 272 2 600 272 2 Wisconsin 1 11 SERIAL NUMBER LOCATION SEE FIGURE 1 4 A serial number plate is affixed to the left rear front of the turntable If the serial number plate is damaged or missing the machine serial number is stamped on the left side of the frame between front and rear wheels below turntable bearing In addition the last five digits of the serial number are stamped on top of the fly and base end of the boom and on the left side of the turntable 1 10 JLG Lift 3120240 SECTION 1 SPECIFICATIONS S
66. 30 31 32 ENGINE OIL HYDRAULIC FILTER ELEMENTS HYDRAULIC FLUID SIGHT GAUGE ARE ON OPPOSITE SIDE OF MACHINE Key to Lubrication MPG Multi Purpose Grease NOTE IT WILL BE NECESSARY TO SWING EPGL Extreme Pressure Gear Lubricant BOOM OVER SIDE OF THE FRAME AND EO Engine Oil REMOVE FRAME SHIELD TO GAIN ACCESS E A R Extend A Reach TO GREASE FITTING 18 Figure 1 2 Lubrication Chart Sheet 1 of 2 1 6 JLG Lift 3120240 SECTION 1 SPECIFICATIONS INDEX COMPONENT NUMBER TYPE LUBE amp METHOD INTERVAL NO LUBE POINTS HOURS 1 Wheel Drive Hub Fill Plug 1 2 Full EPGL SAE 90 50 2 years 2 Slave Leveling Cylinder Barrel End 1 Grease Fitting MPG Pressure Gun 150 3 Slave Leveling Cylinder Rod End 1 Grease Fitting MPG Pressure Gun 150 4 Rotary Platform Control Stand If Equipped 2 Grease Fittings MPG Pressure Gun 150 Platform Pivot 1 Grease Fitting MPG Pressure Gun 150 5 Rotary Worm Gear If Equipped 1 Grease Fitting MPG Pressure Gun 150 6 Platform Hinges 2 Grease Fittings MPG Pressure Gun 150 7 Platform Latch amp Control Handle Slide Locks N A SAE 10 Oil Can A R 8 Telescope Cylinder Sheave If Equipped 1 Grease Fitting MPG Pressure Gun 150 9 Swing Bearing Remote Access 2 Grease Fittings MPG Pressure Gun 150 10 Lift Cylinder
67. 4 by pressing evenly around O D of seal Use care to avoid cocking 6 Install shaft 7 into housing Support the inner race of bearing 3 when pressing shaft into bearing 7 Install gasket 2 Align properly After installing all the remaining internal components of the brake install bearing 18 Properly support the shaft when press ing the bearing onto shaft JLG Lift 2 75 SECTION 2 PROCEDURES Housing Gasket Bearing Seal Spring Retainer Springs Shaft Torque Pin Primary Disc 10 Springs 11 Rotating Discs 12 Statlonary Discs BACK OF SEAL MUST SE INSTALLED FLUSH TO SURFACE OF HOUSING 13 Piston 14 Back Up Ring 15 O Ring 16 Back Up Ring 17 O Ring 18 Bearing 19 Bleeder Screw 20 Plug 21 Power Plate 22 Bolts 23 Pressure Rellef Valve Figure 2 41 Swing Brake Assembly Ausco Machines Built Prior to May 1992 2 76 JLG Lift 3120240 SECTION 2 PROCEDURES 10 Install the power plate sub assembly Use a shop press to evenly lower plate into position There should be no gap at the O D when the power plate is properly seated against housing If a shop press is not available use the assembly bolts 22 Tighten sequentially one turn at a time until the power plate is properly seated Torque to 50 60 ft Ibs 68 81 NM If replacement of pressure relief valve is necessary install 1 2 to 3 4 turns beyond finger tigh
68. 7 cm pitch 14 in 36 cm or 28 pitches 0 42 in 1 07 cm 0 625 in 1 59 cm pitch 15 in 38 cm or 24 pitches 0 45 in 1 14 cm 0 75 in 1 91 cm pitch 15 in 38 cm or 20 pitches 0 45 in 1 14 cm 1 in 2 54 cm pitch 14 in 36 cm or 14 pitches 0 42 in 1 07 cm 1 25 in 3 18 cm pitch 15 in 38 cm or 12 pitches 0 45 in 1 14 cm 1 75 in 4 45 cm pitch 14 in 36 cm or 8 pitches 0 42 in 1 07 cm 2 in 5 08 cm pitch 14 in 36 cm or 7 pitches 0 42 in 1 07 cm 2 8 CYLINDER CHECKING PROCEDURE Cylinders With Single Counterbalance Valve NOTE Cylinder checks must be performed any time a cylin der component is replaced or when improper system operation is suspected Cylinders Without Counterbalance Valves Steer Cylinder and Master Cylinder 3 3120240 Using all applicable safety precautions activate engine and fully extend cylinder to be checked Shut down engine Carefully disconnect hydraulic hose from retract port of cylinder There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should be no further leakage from the retract port Activate engine and extend cylinder If cylinder retract port leakage is less than 6 8 drops per minute carefully reconnect hose to port and retract cylinder If leakage continues at a rate of 6 8 drops per minute or more cylinder repairs must be made With cylinder fully
69. 8 Bar Vickers Proportional Valve 1 6 PRESSURE SETTINGS NOTE All pressure are given in pounds per square inch psi with the metric equivalent Bar in parentheses Racine Proportional Valve Racine Main Relief 2800 psi 193 06 Bar Drive 2800 psi 193 06 Bar Lift Up 2800 psi 193 06 Bar Lift Down 1100 psi 75 85 Bar Swing 1000 psi 68 95 Bar Vickers Proportional Valve w o Tele Vickers Drive 3000 psi 206 85 Bar Lift Up 2500 psi 172 38 Bar Lift Down 1200 psi 82 74 Bar Swing 1100 psi 75 85 Bar Accessory Main Relief 3200 psi 220 64 Bar Sequence Cartridge 450 psi 31 03 Bar Pressure Reducing 600 psi 41 37 Bar 1 8 JLG Lift Vickers Drive 3000 psi 206 85 Bar Lift Up 2500 psi 172 38 Bar Lift Down 1500 psi 103 43 Bar Telescope In 2500 psi 172 38 Bar Telescope Out 1500 psi 103 43 Bar Swing 1200 psi 82 74 Bar Main Relief 3200 psi 220 64 Bar Sequence Cartridge 400 psi 27 58 Bar Pressure Reducing 600 psi 41 37 Bar 3120240 SECTION 1 SPECIFICATIONS 3 Stack Racine Bang Bang Valve Main Relief 2500 psi 172 38 Bar Steer 2000 psi 137 9 Bar 4WD Steer Pressure 2000 psi 137 9 Bar Extend A Reach Racine Valve Extend Up 2500 psi 172 38 Bar Extend Down 800 psi 55 16 Bar NOTE Refer to Section 2 for pressure setting procedures
70. AR WHEELS ARE BLOCKED DISENGAGE DRIVE HUBS OPTIONAL 4WD ALL HUBS MUST BE DISENGAGED 1 Making sure machine is on a level surface and rear wheels are blocked disengage drive hubs Optional AWD all hubs must be disengaged Make up an adapter with an air regulator remove filler cap on hydraulic tank and install regulator Attach air supply to the regulator and set regulator to 2 5 psi 0 14 0 34 Bar A CAUTION DO NOT EXCEED 5 PSI 0 34 BAR INTO HYDRAULIC TANK MORE THAN 5 PSI 0 34 BAR WILL CAUSE DAMAGE TO THE HYDRAULIC TANK 4 Activate machine hydraulic system from platform control station 5 Place LOW ENGINE HIGH DRIVE SPEED and HIGH WHEEL MOTOR SPEED control switches to their respective HIGH positions 6 Depress footswitch and activate DRIVE CONTROL LER to FORWARD position 7 Using a suitable lifting equipment lift front of machine and place a 6 in 15 2 cm high block under right front wheel 8 Lower machine so both of the lockout cylinders are oscillated one extended the other retracted 9 Use suitable containers to retain any residual JLG Lift hydraulic fluid place containers under each lockout cylinder 2 87 SECTION 2 PROCEDURES 10 With DRIVE CONTROLLER activated and engine at 5 Carefully activate SWING control lever and position idle open all four bleeder screws two on each lock boom over right side of machine t cylinder t a time th SE dod ae
71. CCW Mechanical preload between the carburetor and actuator is to large this should be no greater than 1 2 to 1 ball dia Ref to page 43 par 1 Automatic Choke Adjustment Procedure For all JLG 1 IL and 2 3L Ford carbureted engines 3120240 JLG Lift makes contact with throttle lever stop Failure to do so will burn out actuator NOTE Early machines are at idle until a function is acti vated Later machines are at idle only at platform without footswitch activated Therefore when setting low engine speed on later machines it will not be necessary to disconnect bang bang dump valve wire or operate a bang bang function Just activate foot switch to get low engine 2 29 SECTION 2 PROCEDURES CHOKE VACUUM PULLOUT IDLE SPEED SCREW THROTTLE LEVER IDLE AIR MIXTURE THROTTLE ROD LINKAGE HIGH ENGINE NO LOAD BUFFER SCREW PRECISION GOVERNOR ACTUATOR Figure 2 6 Precision Governor Adjustment Ford Sheet 1 of 2 2 30 JLG Lift 3120240 SECTION 2 PROCEDURES LOW MID ENGINE ADJUSTMENT PC BOARD Note All pots should be sealed with finger nail polish after all adjustment are completed Se PRECISION GOVERNOR CONTROLLER Figure 2 7 Precision governor Adjustment Ford Sheet 2 of 2 3120240 JLG Lift 2 31 SECTION 2 PROCEDURES ACTUATOR ROD THROTTLE LEVER THROTTLE LEVER STOP SLIDE PIN 2
72. DURES To Be Performed In Sequence Step 1 Step 2 etc 5 Z Connect 12 V D C jumper wire to dump valve coil DUMP VALVE Adjust to 500 PSI 31 Bar 50 PSI 3 4 Bar Monitor pressure gauge at re lief valve Remove jumper wire SEQUENCE VALVE RELIEF VALVE Install pressure gauge at quick disconnect SEQUENCE VALVE ADJUST STEP 1 Figure 2 14 Vickers Proportional Valve Pressure Setting Machines Built To Present Sheet 1 of 4 Updated 9 15 00 3120240 JLG Lift 2 41 SECTION 2 PROCEDURES Activate Lift Down Adjust to 550 PSI di 37 9 Bar PRESSURE REDUCING VALVE 3unss3tud Install pressure gauge at quick disconnect on regulated port PILOT PRESSURE ADJUST STEP 2 Figure 2 15 Vickers Proportional Valve Pressure Setting Machines Built To Present Sheet2 of 4 Updated 9 15 00 2 42 JLG Lift 3120240 SECTION 2 PROCEDURES Lift Down Adjust 1100 PSI 75 85 Bar A Side Lift Up Adjust 2500 PSI 172 4 B Side Plus 150 PSI 10 3 Bar Minus O Drive Adjust 3000 PSI 206 85 Bar Swing Adjust 1200 PSI 82 7 Bar Control Valve Assembly Vickers 3 Section Swing Adjust Right and Left Monitor gauge at quick connect on rellef valve Lock turntable and activated Swing Right Turn adjustment screw CW to increase pressure CCW to decrease pressure Early Machines add shims to increase pressure rem
73. E PIN 2 2 36 Figure 2 10 Addco Actuator Adjustments F3L912 JLG Lift 3120240 SECTION 2 PROCEDURES ACTUATOR CABLE ADDCO ACTUATOR ACTUATOR CABLE LIMIT LOW ENGINE SLIDE PIN 2 3120240 Figure 2 11 Addco Actuator Adjustments F3L1011 JLG Lift 2 37 SECTION 2 PROCEDURES 2 21 PRESSURE SETTING PROCEDURES 2 38 a Racine Proportional Valve Pressure Setting Machines Built Prior To Mid 1987 are shown in Figure 2 12 and 2 13 Vickers Proportional Valve Pressure Setting Machines Built To Present are shown in Figure 2 14 2 15 2 16 and 2 17 Mickers Proportional Valve Pressure Setting Machines Built Prior To 1989 With Accessory Valve are shown in Figure 2 18 2 19 2 20 and2 21 JLG Lift Solenoid Valve Pressure Settings Machines Built Prior To May 1992 With Steer Wheel are shown in Figure 2 22 Pressure And Flow Settings Machines Built Prior To May 1992 With Steering Wheel are shown in Figure 2 23 Vickers All Hydraulic Pressure Setting are shown in Figure 2 24 2 25 2 26 and 2 27 Solenoid Valve Pressure Settings Machines Built To Present are shown in Figure 2 28 and 2 29 Extend A Reach Valve Pressure and Speed Settings Model 40H 6 are shown in Figure 2 30 3120240 SECTION 2 PROCEDURES ADJUSTMENT FOR SWING 1 Place Gauge At Swing Motor 2 Engine At Low RPM 3 Turntable
74. END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 2000 POUNDS 907 KG THE FOUR CAPSCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE IF A HYDRAULIC PRESS IS AVAILABLE 3000 LBS 1362 KG MAXIMUM THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAP SCREWS 15 16 17 18 19 Remove case seal 4 from housing 19 then remove bleeder screw 3 from end cover 2 Remove piston 7 from end cover 2 Remove o ring 5 back up ring 6 0 ring 8 and back up ring 9 from piston 7 Remove stack assembly consisting of shaft 10 sta tors 11 return plate 13 and rotors 12 from housing 19 Remove dowel pins 20 springs 14 15 and spring retainer 16 from housing 19 20 Remove retaining ring 17 from housing 19 21 Remove shaft by pressing or using a soft mallet on male end of shaft 10 22 Remove retaining ring 21 and bearing 18 from shaft 10 23 Press rotary oil seal 22 from housing 19 Inspection 1 Clean all parts thoroughly 2 Closely inspect all parts for excessive wear cracks and chips Replace parts as necessary 3 Discard seals and o rings 4 Closely inspect bearings and bearing contact sur faces Replace as necessary NOTE Bearings may be re used if after thorough inspec 3120240 tion they are found to be in good condition Assembly NOTE DISC 11 Lubricate all seals and o rings with clean hyaraulic oil prior to assembly Clean all parts thoroughly before assembly Press new
75. ENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES 12 With barrel clamped securely and while adequately supporting the rod insert the piston end into the barrel cylinder Ensure that the piston loading o ring and seal ring are not damaged or dislodged 13 Continue pushing the rod into the barrel until the cyl inder head gland can be inserted into the barrel cyl inder or if applicable until the cylinder threads engage the threads of the barrel 14 If applicable secure the cylinder head gland using suitable spanner type wrench in the holes provided 15 If applicable secure the cylinder head retainer using a suitable spanner type wrench in the holes pro vided 16 After the cylinder has been reassembled the rod should be pushed all the way in fully retracted prior to the reinstallation of any holding valve or valves 17 If applicable install the cartridge type holding and fittings in the rod port block using new o rings as applicable See Table 2 2 Holding Valve Torque Specifications A CAUTION IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON THE MACHINE EXTREME CARE SHOULD BE USED TO INSURE THAT THE OUTER END OF THE ROD IS SUPPORTED USE EITHER A TRAVELING OVERHEAD HOIST FORKLIFT OR OTHER MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE EXTENDING ROD NOTE Steps 18 through 21 apply to the Boom Telescope Cylinders 18 Elevate the barrel end of the cylinder to a
76. Figure 2 8 Addco Actuator Adjustments F2L511 2 32 JLG Lift 3120240 SECTION 2 PROCEDURES 2 18 THROTTLE CHECKS AND ADJUSTMENTS WISCONSIN ENGINE SEE FIGURE 2 9 Checks 1 Check that carburetor throttle link is located at top of governor arm Check that spring is located at first or second spring hole from top of governor arm First hole is prefera ble Second hole can be used when trying to stop surging Adjustments 1 3120240 Disconnect the actuator rod from the arm With the aid of an assistant start the engine from platform and allow it to come up to operating temperature Adjust carburetor idle screw until engine runs at 1800 RPM Shut down engine Reattach actuator rod to arm making sure that low engine setting remains the same If necessary adjust slide pin to contact low engine limit switch at 1800 RPM Shut down engine With the aid of an assistant start engine from plat form and allow to come up to operating tempera ture Disconnect proportional dump valve wire Activate footswitch Turn on HIGH ENGINE switch Hold drive controller in full drive position Adjust slide pin to contact high engine limit switch at 2400 RPM Shut off all switches and controllers Recon nect proportional dump valve wire JLG Lift NOTE Early machines are at idle until a function is acti vated Later machines are at idle only at platform without footswitch activated Therefore when s
77. HEX 1 5 8 12 100 110 ft Ibs THDS 136 149 NM Description Nut Setscrew Torque Value Torque Value Wet Dry Lift Cylinder 600 ft Ibs 200 in Ibs 814 Nm 23 Nm Slave Cylinder 80 ft Ibs 100 in Ibs 109 Nm 12 Nm Master Cylinder 80 ft Ibs 100 in Ibs 109 Nm 12 Nm Steer Cylinder 80 ft Ibs 100 in Ibs 109 Nm 12 Nm Lockout Cylinder 80 ft Ibs 100 in Ibs 109 Nm 12 Nm Telescope Cylin 600 ft Ibs 200 in Ibs der 814 Nm 23 Nm Extend A Reach Lift Cylinder 200 ft Ibs 100 in Ibs 271 Nm 12 Nm Slave Cylinder 200 ft Ibs 100 in Ibs 271 Nm 12 Nm NOTE After torquing piston nut spot drill cylinder rod for set 2 12 screws 2 10 CYLINDER REMOVAL AND INSTALLATION Telescope Cylinder Removal 1 Be sure boom is fully retracted and in a horizontal position Shut down engine Support boom basket end with a prop See Figure 2 2 Remove boom end cover A CAUTION HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYSTEM 4 Tag and disconnect hydraulic lines to telescope cyl NOTE JLG Lift inder Use suitable container to retain any residual hydraulic fluid Cap hydraulic lines and ports Remove the two setscrews that retain the telescope cylinder pin to the base boom Using a suitable brass drift car
78. ITCH SHOWN 319 MORIZONTAL PROPORTIONAL DUMP RELAY Dec BE 1 t 1 I I 7 Qe YELLOW o SELECT RELAYS Ix HIGH ENGINE SELECT OMRGLAY RELAY x 3AMP ENDING THROTTLE C B Figure 3 9 Wiring Diagram Standard Deutz F21511 f31912 amp Engine W Hydraulic Controls Sheet 1 Of 2 3 28 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING 28PEEO zeo 2848 START RELAY 1280992 F Figure 3 10 Wiring Diagram Standard Deutz 221511 131912 amp Wisconsin Engine W Hydraulic Controls Sheet 2 Of 2 3120240 JLG Lift 3 29 SECTION 3 TROUBLESHOOTING I 1 ROTAT 8 33 8 5 J S SSSR S RPR ENG SPEED NOTE MACHINES BUILT BEFORE 1 94 WILL NOT HAVE H PROP DUMP B 8 DUMP ROTATE amp LEVEL SWITCHES 22020 20203202020 22 70 20 20 CUTOUT RT START LOCKOUT 2 Figure 3 11 Wiring Diagram Standard Deutz F311011 Engine W Standard Controls Sheet 1 Of 2 3 30 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING 68 lel eU eus l 50 ind F m OIL P
79. JLG Lift 2 3 SECTION 2 PROCEDURES Proportional Control Valve Vickers CMX series valves provide a power output matching that required by the load A small line connected to a load sensing port feeds load pressure back to the pump The pump senses the difference between the load and pump outlet pressures and varies the pump displacement to keep the difference constant This differential pressure is applied across the valves meter in spool with the effect that pump flow is determined by the degree of spool opening independent of load pressure Return lines are connected together simplifying routing of return flow and to help reduce cavitation Load sensing lines connect through shuttle valves to feed the highest load signal back to the pump Integral actuator port relief valves anti cavi tation check valves and load check valves are standard The load drop check prevents any drop of a suspended load before upward movement Relief Valves Main relief valves are installed at various points with the hydraulic system to protect associated systems and com ponents against excessive pressure Excessive pressure can be developed when a cylinder reaches its limit of travel and the flow of pressurized fluid continues from the system control The relief valve provides an alternate path for the continuing flow from the pump thus preventing rupture of the cylinder hydraulic line or fitting Complete failure of the system pump
80. Lift Using a suitable press press new bearing cups 5 9 with large inside diameters facing out into hub 8 counterbores Place bearing cone 4 into bearing cup 5 in small end of hub Press new seal 3 into hub counterbore with flat metal side facing in Use a flat object to ensure that seal is pressed evenly and is flush with hub face Lower hub onto spindle 2 with large open end up Place bearing cone 10 over end of spindle and into bearing cup 9 Place bearing shim 11 over end of spindle and against bearing cone 2 65 SECTION 2 PROCEDURES A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION 7 10 11 12 13 14 15 16 NOTE 17 18 19 20 2 66 Install new retaining ring 12 completely into spindle groove and against bearing shim Ensure retaining ring is entirely in groove Place internal gear 13 onto end of spindle Place input shaft assembly into spindle bore with unsplined end facing out Place narrow thrust washer 19 over input shaft 14 with counterbore side facing spindle Place o ring 29 into hub counterbore Use petroleum or grease to hold o ring in place Slight stretching of o ring may be necessary to insure proper seating Place carrier assembly on a flat surface with large gears up and positioned as shown in Figure 2 26 Find punch marked tooth on each large gear and locate at 12 o clock straight up from each planet pin Ma
81. ND Elevation Switch Drive Control Switch Mid Speed Switch Starter Switch coU ro moou Set Main Speed Before Setting Overspeed NOTE These settings are factory set Start Lockout Fac tory Adjust and Overspeed They are conformally coated by P G and should not need to be reset Assuming that the Actuator and Controller are mounted the wiring is run and checked and that the linkage is properly installed proceed as follows 1 3120240 Turn ignition switch on Do not start engine Actuator should kick toward max fuel once and then imme diately return to min fuel If not see Troubleshoot ing Use multimeter to check battery voltage at battery terminals and record Now check voltage at the machine connection points for terminals A amp B of the 8 pin connector on the E 331 A is B is Voltage reading should be the same as at battery If not shut down and correct wiring Hold the linkage back by hand so as to control engine speed manually Start engine set vehicle controls to obtain High Engine speed gradually release the linkage and adjust the speed set as needed to set the speed as desired If engine speed surges reduce Gain a little as required CCW Re check voltage between terminal A amp B as in step 2 Voltage reading should be between 13 5 14 6 VDC Carefully adjust Gain You are looking for the best compromise between quick response and good sta NOTE JLG Lift
82. OOLANT SYSTEM NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING OR BOOM SAFETY PROP HAS BEEN ENGAGED BEFORE MAKING ADJUSTMENTS LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE SHUT OFF ALL POWER CONTROLS BATTERY SHOULD ALWAYS BE DISCONNECTED DURING REPLACEMENT OF ELECTRICAL COMPO NENTS KEEP ALL SUPPORT EQUIPMENT AND ATTACH MENTS STOWED IN THEIR PROPER PLACE USE ONLY APPROVED NONFLAMMABLE CLEANING SOLVENTS JLG Lift a EFFECTIVITY CHANGES REVISON LOG Aug 1985 Original Issue Nov 1985 Revised Oct 1998 Revised Aug 1999 Revised October 11 2001 Revised b JLG Lift 3120240 TABLE OF CONTENTS SUBJECT SECTION PARAGRAPH PAGE NO SECTION A INTRODUCTION MAINTENANCE SAFETY PRECAUTIONS A A General s TP Cree nter eae atio E EHE Sa St SE a A B Hydraulic System Safety ede pee tk Re Gee een Gn a RS a A C Maintenance susce ac AR CERTE a badd ea Pace RO a EEFFEGTIVITY CEIANGES er oda enne rt denk bog anced ue ke Due deka wane b TABL E OF CONTENTS eremo tren re a e E Pep mde EIST OFIBEUSTRATIONS rua rem oe a a E eue im ru E mbar ms sues Ie A DE Sas DES
83. PROP OR PROVIDING ADEQUATE OVERHEAD SLING SUPPORT AND OR BLOCKING 2 60 b Attach an adequate support sling to the boom and draw all slack from sling Prop or block the boom if feasible c From underside of the machine frame remove bolts and lockwashers which attach the retaining yoke of the rotary coupling to the coupling housing A IMPORTANT HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF CONTAMINANTS INTO THE SYSTEM d JLG Lift Tag and disconnect the hydraulic lines from the fittings on the top and sides of the rotary coupling Use a suitable container to retain any residual hydraulic fluid Imme diately cap lines and ports If machine is not equipped with a rotary coupling tag and disconnect hydraulic lines running through center of turntable and frame Use a suitable container to retain any residual hydraulic fluid Immediately cap lines and ports Attach suitable overhead lifting equipment to the base of the turntable weldment Use a suitable tool to scribe a line on the inner race of the swing bearing and on the underside of the turntable This will aid in aligning the bearing upon installation Remove the bolts nuts and washers which attach the turntable to the bearing inner race Discard the nuts and bolts Use the lifting equipment to carefully lift the complete turntable assembly from the bear ing Ensure that no damage occurs to t
84. REA 1 Connect a suitable auxiliary hydraulic power source to the cylinder port block fitting A WARNING DO NOT FULLY EXTEND CYLINDER TO THE END OF STROKE RETRACT CYLINDER SLIGHTLY TO AVOID TRAPPING PRES SURE 2 Operate the hydraulic power source and extend the cylinder Shut down and disconnect the power source Adequately support the cylinder rod if appli cable A CAUTION CYLINDERS WITH DOUBLE HOLDING VALVES BEFORE REMOV ING HOLDING VALVES CRACK BLEEDERS TO RELEASE PRES SURE 3 If applicable remove the cartridge type holding valve and fittings from the cylinder port block Dis card o rings 4 Place the cylinder barrel into a suitable holding fix ture Tap around outside of cylinder head retainer with a suitable hammer to shatter loctite 5 Using a suitable spanner wrench loosen the cylin der head retainer if applicable and or cylinder head gland and remove from cylinder barrel 6 Attach a suitable pulling device to the cylinder rod port block end or cylinder rod end as applicable A IMPORTANT EXTREME CARE SHOULD BE TAKEN WHEN REMOVING THE CYL INDER ROD HEAD AND PISTON AVOID PULLING THE ROD OFF CENTER WHICH COULD CAUSE DAMAGE TO THE PISTON AND CYLINDER BARREL SURFACES JLG Lift 2 9 SECTION 2 PROCEDURES 10 11 12 13 With the barrel clamped securely apply pressure to the rod pulling device and carefully withdraw the complete rod assembly from the cylinder bar
85. RES OIL TEMP ALTERNATOR x Le dz 78 i OIL OIL SWITCH SENSOR 1 1 014014 4 12 VOLT DC BATTERY 1281502 E Figure 3 12 Wiring Diagram Standard Deutz F311011 Engine W Standard Controls Sheet 2 Of 2 3120240 JLG Lift 3 31 SECTION 3 TROUBLESHOOTING HORIZONTAL SWITCH SHOWN ABOVE HOUR HORIZONTAL METER 1 4 ON ENG TERM STRIP BLUEBLK ET E pacen Ti VELLOW RI ORANGE BLUE BROWN BLU 9 2sPtED YELLOW BLU t orvs RELAY HIGH DRIVE BLUEOR RELAY HGH ENGINE BROWN BLK BLACK OR HORN RELAY ORANGE a SELECT ORANGE AD RELAY MID ENG YELLOW F ORANGEBL 1 Lee we we ONENG LL 3 TERM STRIP T START LOCKOUT renee P emm que iA 5 4 i ii qmm PROPORTIONAL YELLOW SEL amp CT SELECT onanaeno YELLOW d 5 5 id di IGNITION SELECT E BLUE SLX ELACKBLU iii 10 AMP GROUND CONTROL Figure 3 13 Wiring Diagram Standard Deutz F311011 Engine W Hydraulic Controls Sheet 1 Of 2 3 32 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING peres dee A he 3 vaiows nl GRAY WHT 22 WHTVEL zl a
86. RIZONTAL LIMIT SWITCH SHOWN ABOVE HORIZONTAL IPROPONTIONAL pOUMP RELAY 85 SELECTA 1 4 lu Qe zi i i Bg YELLOW 1 1 VIS 2 SELECT BANG i HR e O Erta el anaw H Em YG S 3 Cian a auma 2 o 3 5 _ mc Ri aster Cum 8 2 SPEED DRIVE o9 INO d 5 BIB D RELAY 15 o9 ehe KOLE RUM T M 85405 0 HIGH ENGINE Q ER E9 HORN RELAY am YELLOW Ax DRIVE eme PEERED T Sao ew CUT OUT RELAY YECCOWSLK T i CRE sms 0 0 70777775 SELECT RELAY 9 OE ETVBLU ona woes cuj LEVEL UP YELLOW START J E A STEER LEFT STEER RIGHT DRIVE FORWARD DRIVE REVERSE 5 TILT ALARM 12 VOLT FROM THE BATTERY 12 VOLT WHEN THE IGNITION SWITCH IS ON 2 CHOKE DUAL FUEL SELECT SWITCH RD 1 66 MASTRR Ho o SWITCH loco 3 36 Figure 3 17 Wiring Diagram Standard Ford Dis Engine W Hydraulic Controls Sheet 1 Of 2 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING 3120240 mm E NIU ee a DRIVE 1 DE ivi BANG acesune SANG switch VALVE ROTATE STEER 4 zii E
87. Remove disconnect rod 36 from cap and remove o rings 33 35 from cover cap Discard o rings d If necessary remove pipe plug 39 from cover e Clean and inspect parts in accordance with paragraph b Replace parts as necessary f If removed screw pipe into cover g Slip o ring 33 over cover cap and against face h Place o ring 35 into cover cap internal groove Disconnect rod may be used to push o ring into groove i Place cover cap into cover with large hole located over pipe plug Secure cover cap to cover with two bolts Torque bolts to 70 80 in Ibs 7 9 9 0 NM j Place disconnect cap over cover cap with nipple facing out and secure with two bolts Torque bolts to 70 80 in Ibs 7 9 9 0 NM k Turn cover over and push disconnect rod into cover cap Rod will be held in place by friction from o ring Carrier Assembly a Drive anti roll pin 24 into planet 23 using a suitable punch b Using a suitable press press planet shaft from carrier 22 After planet shaft is removed drive anti roll pin from shaft c Remove cluster gear 28 and thrust washers 25 from carriers d Remove sixteen needle rollers 26 from cluster gear bore e Remove spacer 27 from cluster gear bore and remove second set of sixteen needle rollers 26 f Repeat steps a through e for remaining two cluster gears g Clean and inspect all parts in accordance with paragraph b Replace parts as necessary h Appl
88. Repeat steps 3 through 5 for the remaining Y nut The switch is now level 7 Individually push down on one corner at a time there should be enough travel to cause the switch to trip If the switch does not trip in all three tests the flange nuts have been tightened too far Loosen the X nut and repeat steps 3 through 7 Voltmeter Adjustment 1 Park machine on a flat level surface Ensure machine is level and tires are filled to rated pressure 2 If engine is not running turn ignition switch to ON 3 Connect black lead of voltmeter to ground and red lead to yellow wire protruding from pot on bottom of sensor 4 Adjust leveling nuts to obtain the highest possible voltage reading 5 Check Voltage at trip point in all four directions If voltage reading is not symmetrical repeat step 4 above 2 13 HORIZONTAL HIGH SPEED CUTOUT SWITCH ADJUSTMENT PROCEDURE Adjust switch to trip when boom reaches 0 degrees 0 degrees 3 degrees JLG Lift 2 19 SECTION 2 PROCEDURES 2 14 GOVERNOR CHECKS AND ADDCO ADJUSTMENT FORD NOTE All governor adjustments must be made with Addco throttle actuator disconnected Adjustments Refer to Figure 2 5 2 6 and Checks Refer to Figure 2 4 2 7 1 Check governor drive belt tension A belt in opera tion for 10 minutes or more should be set at 100 ft Ibs 135 Nm 2 Check length of spring spreader adjustment from centerline of eye to
89. S N 33476 2 82 2 45 Drive Brake Mico Machines Built From S N 33476 To 2 84 2 46 Swing Brake Mico Machines Built From S N 33476 to 2 86 2 47 Basket Rotator Brak uu u l u isle Relax ha where Shea ek ee ee pu la 2 88 2 48 Tape Replacement 1 2 92 2 49 Capacity Indicator Dial 1 2 92 3 1 Wiring Diagram Dual Fuel Ford Or 3 20 3 2 Wiring Diagram 110v Generator 2 12 3 21 3 3 Wiring Diagram 110v Generator 2 3 22 3 4 Wiring Diagram Platform Console W all Hydraulic 3 23 3 5 Wiring Diagram Platform Console Standard Sheet 1 2 3 24 3 6 Wiring Diagram Platform Console Standard Sheet 2 012 3 25 3 7 Wiring Diagram Standard Deutz 21511 131912 amp Wisconsin Engine W Standard Controls Sheet 1 2 3 26 3 8 Wiring Diagram Standard Deutz 2214511 31912 amp Wisconsin Engine W Standard Controls Sheet 2 2 3 27 3 9 Wiri
90. S UNDER SPRING TENSION OF APPROXIMATELY 1500 POUNDS 681 KG THE FOUR CAPSCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE IF A HYDRAULIC PRESS IS AVAILABLE 3000 LBS 1362 KG MINIMUM THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAP SCREWS AND LOCKWASHERS 2 10 Tap cover with a soft mallet in order to dislodge bearing 7 from cover Remove o ring 6 square ring 5 pipe plug 3 and bleeder screw 13 from end cover Remove piston 10 from end cover by inserting two 1 4 20 UNC bolts into threaded holes in piston By turning and pulling piston can be removed from bore Remove o ring 8 and back up ring 9 o ring 11 and back up ring 12 from piston Remove separators 19 from housing 26 Remove shaft assembly consisting of shaft 15 discs 16 20 and friction plates 18 springs 17 snap ring 14 and bearings 7 24 from housing by pressing or using a soft mallet on male end of shaft Remove springs 17 from between tabs of discs 16 20 Remove bearing 7 24 from shaft 15 with appropriate bearing puller The discs and friction discs will then slide off male end of shaft Remove snap ring and shaft Remove dowel pins 23 springs 21 22 and o ring 25 from housing 3120240 Figure 2 39 Swing Brake Assembly Mico Machines Built Prior To May 1992 JLG Lift 2 71 SECTION 2 PROCEDURES Cleaning and Inspection 1 Clean all parts thoroughly 2 Closely inspect all p
91. SI 172 4 Bar with engine at low RPM activate level function SET TELESCOPE PRESSURE With a pressure gauge at quick disconnect and engine at low RPM bottom out tele in and adjust to 2000 PSI 137 9 Bar for 2 Section Boom 2500 PSI 172 4 Bar for 3 Section Boom Then bot tom out tele out and adjust to 1500 PSI 103 4 Ban Figure 2 23 Pressure And Flow Settings Machines Built Prior To May 1992 With Steering Wheel 2 50 JLG Lift 3120240 SECTION 2 PROCEDURES Install Gauge At Quick Disconnect On Tee At 5 Z Lower Port KLEE lt gt eie cS mt CONTROL VALVE ASSEMBLY VICKERS 4 SECTION STEP 1 SETTING SEQUENCE PRESSURE 1 Plug pressure gauge into quick disconnect on Vickers Valve 2 Start engine from ground control this will energize dump valve 3 Monitor pressure gauge while making adjustment at sequence cartridge 400 600 PSI 27 6 41 4 Bar 4 Remove pressure gauge Adjust Pressure Reducing Cartridge To 600 PSI 41 4 Bar ADJUST MAIN RELIEF CARTRIDGE Adjust Sequence Cartridge To 400 600 PSI 27 6 41 4 Bar Accessory Valve Note On all hydraulic system dump Is Assembly activated when switched to Ground Control STEP 2 SETTING PILOT PRESSURE 1 Plug pressure gauge into quick disconnect on Accessory Valve 2 Activate Lift Down 3 While monitoring pressure gauge adjust pressure reducing cartridge to 600 PSI 41 4 Bar 4 Rem
92. T SUCH REPLACEMENT HARDWARE MEETS JLG SPECIFICATIONS USE OF GENUINE JLG HARDWARE IS HIGHLY RECOMMENDED o Spray a light coat of Safety Solvent 13 to the new bearing bolts Then apply a light coating of Loctite 271 to the new bearing bolts and loosely install the bolts and washers through the frame and outer race of bearing A CAUTION IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED FOR TIGHTENING THE BEARING ATTACH MENT BOLTS THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE p Following the Torque Sequence diagram shown in Figure 2 35 tighten the bolts an torque bolts to 80 ft Ibs 109 NM wet q remove the lifting equipment from the bearing r Use suitable lifting equipment to carefully posi tion the turntable assembly above the machine frame s Carefully lower the turntable onto the swing bearing ensuring that the turntable and bearing align as noted in step i above A CAUTION IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT WRENCH IS USED FOR TIGHTENING THE BEARING ATTACH MENT BOLTS THE TORQUE SETTING ACCURACY OF THE TOOL SHOULD BE CHECKED PRIOR TO USE 2 62 JLG Lift t Spray a light coat of Safety Solvent 13 to the new bearing bolts Then apply a light coating of Loctite 271 to the new bearing bolts and install the bolts washers and nuts through the turntable and inner race of the bearing u Following the Torque Sequence diagram shown in Figure 2
93. ack up ring 9 new o ring 11 and new back up ring 12 on piston 10 Insert pis ton 10 into end cover 4 being careful not to shear o rings or back up rings Inserting 1 4 20UNC bolts in piston may simplify installation 9 Install new o ring 6 new bearing 7 new square ring pipe plug 3 and bleeder screw 13 in end cover 2 Tap cover with a soft mallet in order to dislodge 2 72 JLG Lift 10 Position end cover 4 on housing aligning dowel pins 23 with holes in end cover 11 Install capscrews 1 and lockwashers 2 Tighten evenly to draw end cover 4 to housing and bearing 7 onto shaft 15 Torque capscrews to 55 ft Ibs 75 NM NOTE available a hydraulic press will simplify installation of end cover on housing Clamp cover in position while tightening capscrews 12 Press on inner ring of bearing 7 until it shoulders on shaft 15 to eliminate binding on bearings Be certain to restrain opposite end of shaft to avoid excessive thrust loading on bearing 24 A IMPORTANT PRESS FORCE SHOULD BE LIMITED TO 2000 LBS 907 2 KG MAXIMUM TO AVOID POSSIBLE DAMAGE TO SNAP RING 14 A IMPORTANT IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY RELEASE PRESSURE SHOULD NOT EXCEED 2000 PSI 137 9 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING Bleeding 1 Install brake and connect pressure lines 2 Bleed pressure release section of brake by pressur izing side inlet port and allow
94. act the cylinder rod for alignment Install the cross pin through the base boom section and cylin der rod Secure pin by installing setscrew Align the cylinder rod end attachment point with those of the boom base section If necessary use an auxiliary hydraulic power source to extend and retract the cylinder rod for alignment Install the cross pin through the base boom section and cylin der rod Secure pin by installing setscrew Align the chain attachment assembly holes with the threaded mounting holes at the aft end of the boom by installing the bolts and washers Insert the threaded end of the chain attachment cle vis bolt through the large hole of the chain attach ment weldment Loosely install the jam nut and nut onto the threaded end of clevis bolt Assemble and install the retraction chain attachment and adjustment assembly as follows a Place clevis bolt on bottom plate and place top plate onto clevis assembly Secure clevis bolt with clevis pins washers and new cotter pins 32 33 JLG Lift b Insert chain attach blocks between clevis plates ensuring attachment points are properly aligned Secure block in position with bolts nuts and new cotter pins c Align retraction chains with clevis attach blocks secure chains with clevis pins washers and new cotter pins d Position the bolt end of the extension adjust ment clevis into the boom mounted bracket Secure the chain adjusting assembly by in
95. aded or sustained a shock load A WARNING FAILURE TO DISASSEMBLE THE BOOM ASSEMBLY AND PROP ERLY INSPECT AND OR REPLACE THE BOOM CHAINS AND RELATED COMPONENTS I E SHEAVES PINS SPROCKETS WEAR PADS ETC COULD RESULT IN THE DAMAGE AND OR BREAKAGE OF THE BOOM CHAINS AND OR RELATED COMPO 2 4 JLG Lift 3120240 SECTION 2 PROCEDURES NENTS DAMAGE AND OR BREAKAGE OF THESE ITEMS COULD RESULT IN UNCONTROLLED EXTENSION OR RETRACTION OF THE BOOM ASSEMBLY AND COULD CAUSE SERIOUS INJURY OR DEATH TO PERSONNEL OPERATING THE JLG BOOM LIFT TELESCOPE CYLINDER EXTEND CHAIN ATTACH EXTEND CHAIN RETRACT CHAIN RETRACT CHAIN AND EXTEND CHAIN ATTACH RETRACT CHAIN SHEAVE RETRACT CHAIN ADJUSTMENT Figure 2 1 Typical Three Section Boom Assembly Inspection Procedures 5 Inspect boom chains for the following condition Wear Always inspect that segment of chain that operates over a sheave As the chain flexes over the extend retract sheaves joints and plate edges very gradually wear Chain stretch can be mea sured using a manufacturers wear scale or steel tape When chains have elongated 3 they must be removed and replaced Refer to Table 1 for proper chain specifications and allowable stretch tolerances Peening and wear of chain plate edges are caused by sliding over a chain worn contact face of a sheave or unusually heavy loads All of the above require replacement of the chain and correction of the
96. aged and should not be removed if replacement is not planned Pressure relief valve 23 can be removed and inspected to assure spring loaded ball moves freely and is contamination free Cleaning and Inspection 1 Clean all parts thoroughly 2 Closely inspect all parts for excessive wear cracks and chips Replace parts as necessary 3 Discard seals and o rings 4 Closely inspect bearings and bearing contact sur faces Replace as necessary NOTE Bearings may be reused if after thorough inspection they are found to be in good condition Assembly NOTE Lubricate all seals o rings cylinder of the power plate and piston with clean hydraulic oil prior to assembly 1 Assemble piston 13 into power plate 21 using a shop press being careful not to damage the o rings or back up rings Visually align the center of the cut outs in piston 13 with torque pin 8 holes in power plate 21 Avoid pushing the piston all the way to the bottom of the cylinder in the power plate Try to keep the top surface of the piston flush to 1 8 0 32 cm elow the machined surface of the power plate 2 When pressing the bearing onto the shaft press on the inner race of the bearing and support the shaft properly 3 Rotating discs must be clean and dry Worn or heavily scored rotating discs must be replaced 4 Press bearings 3 into housing 1 Bearing must be seated against shoulder in housing 5 Using a shop press install seal
97. agram 3120240 JLG Lift 3 5 SECTION 3 TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY Boom will swing in only one direction Restricted or broken hydraulic line on fitting Control valve not functioning properly Foreign objects wedged between swing motor pin ionand swing gear Swing control lever not functioning Brake shuttle valve defective Clean repair or replace line or fitting Repair or replace valve Remove objects check for damage and repair or replace component s as required Repair or replace swing control lever Replace shuttle valve Boom swings erratically in either direction Hydraulic system oil low Lack of lubricant on swing gear or speed reducer pinion Swing motor not functioning properly Worn or broken teeth on swing gear or swing motor pinion Swing brake not functioning properly Restrictor valves plugged Replenish oil as necessary Lubricate as required See Lubrication Chart Repair or replace swing control lever Replace gear s as required Repair or replace swing brake Clean or replace restrictor valve 3 6 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING Table 3 3 Turntable Assembly Troubleshooting TROUBLE PROBABLE CAUSE REMEDY POWER PLANT Engine will not start Station power selector switch not in required posi tion Circuit breaker open Defecti
98. alve using High Engine pot See diagram on page 43 E 331 Elec tronics Adjustment Locations Mounting Actuator The Actuator may be mounted in any attitude there is no preferred orientation With no power applied the actuator is spring loaded to the minimum fuel position The Actuator output shaft rotates toward the maximum fuel position against this spring through electrical power from the controller This rotation is CW clockwise on one side of the Actuator and CCW counterclockwise on the other If necessary reverse the Actuator on its mounting plate so that the desired direction of rotation is on the desired side to match the fuel system direction of travel 3120240 SECTION 2 PROCEDURES Before selecting the mounting location consider the link age that will be required to connect the Actuator output arm to the butterfly or fuel valve Read the following sec tion on linkages before deciding on a mounting location 1 Mount Actuator rigidly to the engine location witch will permit a short straight linkage to the carburetor or fuel valve Avoid very hot areas Linkage 3120240 1 4 28 threaded rod and low friction rod end bearings are recommended for linkage materials Keep the linkage as short and as straight as possible The linkage must not rub against the engine brackets hoses etc The linkage must be free of friction and lost motion or slop The following sketch indicates the proper l
99. and for tapering or ovality Replace pin as necessary Inspect upper lift cylinder attach pin for tapering ovality scoring wear or other damage Ensure pin surfaces are protected prior to installation Replace pin as necessary Steps 7 and 8 apply to 3 Section Boom Only Inspect telescope cylinder trunnion attach pin for tapering ovality scoring wear or other damage Replace pin as necessary Inspect extend chain attach clevis pins for wear scoring or other damage Replace pins as neces sary Inspect telescope cylinder rod attach pin for scoring wear or other damage Replace pin as necessary Inspect inner diameter of boom pivot bushing for scoring distortion wear or other damage Replace bushing as necessary Inspect all wear pads for excessive wear or damage Replace pads when worn to within 1 8 inch 3 2 mm of insert Step 12 applies to 3 Section Boom Only Inspect extend and retract chains and chain attach components for cracks stretching distortion or other damage Replace components as necessary Inspect all threaded components for damage such as stretching thread deformation or twisting Replace as necessary Inspect structural units of boom assembly for bend ing cracking separation of welds or other damage Replace boom sections as necessary Assembly NOTE NOTE JLG Lift When installing fly section wear pads install same number and thickness of shims as were rem
100. and top thrust washer 31 from hub Thrust washer may stick inside cover 4 Pry ring gear 30 loose from hub and remove it Remove o ring seal 29 from hub counterbore and discard it 5 Remove input gear 20 and thrust washers 19 21 from input shaft assembly and remove input shaft assembly from hub 6 Lift internal gear 13 and thrust washer 18 from hub Thrust washer may stick to bottom of carrier 7 Remove retaining ring 12 from spindle 2 and lift hub from spindle A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL 8 Remove inside bearing cone 10 and bearing shim 11 3120240 9 Ifnecessary pry seal 3 out of hub using screwdriver or pry bar With seal removed outside bearing cone 4 can be removed 10 If necessary remove inner and outer bearing cones 5 9 using a suitable slide hammer puller A CAUTION WHEN REBUILDING TORQUE HUB REMOVE AND REPLACE ALL O RINGS AND RETAINING RINGS Cleaning and Inspection 1 Thoroughly clean all parts in an approved cleaning solvent 2 Inspect bearing cups and cones for damage pitting corrosion or excessive wear If necessary replace bearings as a complete set ensuring that they remain covered until use 3 Inspect bearing mounting surfaces on spindle hub input shaft and carrier Replace components as nec essary 4 Inspect all geared components for chipped or bro ken teeth and for excessive or uneven wear pat terns 5 Inspect carr
101. arts for excessive wear cracks and chips Replace parts as necessary 3 Discard seals and o rings 4 Closely inspect bearings and bearing contact sur faces Replace as necessary NOTE Bearings may be reused if after thorough inspection they are found to be in good condition Assembly NOTE Lubricate all seals and o rings with clean hydraulic oil prior to assembly 1 Insert new o ring 25 dowel pins 23 and springs 21 22 in housing 26 2 Install new bearing 24 in housing and press until bearing bottoms on shoulder in housing 3 Position new large diameter disc 20 in housing with tabs guided by dowel pins 23 until disc rests on springs 21 22 A IMPORTANT DISCS 16 amp 20 AND FRICTION DISCS 18 SHOULD REMAIN DRY DURING INSTALLATION NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES 4 Place a new friction disc 18 on bottom disc 20 cen tering it as closely as possible Insert one spring 17 on each dowel pin 23 5 Add additional new disc 16 and friction disc 18 and springs 17 as required for specific model 6 Install snap ring 14 on shaft 15 Insert shaft 15 thru friction discs 18 until shaft contacts bearing 24 Press shaft 15 until it shoulders on inner race of bearing 24 A small preload will exist on snap ring 14 at this point 7 Insert separators 19 over spiral pins in housing 26 Separators will contact top of bottom disc 20 when properly installed 8 Install new o ring 8 new b
102. ate drive 4 Slowly turn adjustment in clockwise and watch pressure gauge Continue turning until gauge stops moving approximately 3000 PSI 206 8 Bar 5 Turn adjustment in an additional 1 2 turn this will result in approximately 200 PSI 13 8 Bar higher than the highest Drive relief setting install Pressure Gauge At Quick Disconnect On Teo At Lower Port Control Valve Assembly Vickers 4 Section Figure 2 26 Vickers All Hydraulic Machines Pressure Settings Sheet 3 of 4 3120240 JLG Lift 2 53 SECTION 2 PROCEDURES Set Adjust At 125 PSI 8 6 Bar Set Adjust At 80 to 120 PSI 5 5 NL Relief Valve Assembly Pressure Reducing Valve Assembly STEP 5 SETTING RELIEF AND PRESSURE REDUCING VALVES 1 Plug a low pressure gauge into quick disconnect on Vickers Valve Pressure drain port at end cap 2 Adjust relief all the way in temporary 3 Set pressure reducing valve to 150 PSI 10 34 Bar temporary 4 Reset rellef valve pressure to 140 PSI 9 6 Bar and lock 5 Reset pressure reducing valve to 80 to 120 PSI 5 5 to 8 2 Bar and lock 6 Remove pressure gauge Install a low pressure gauge with a max of 200 t Quick Disconnect PSI 13 8 Bar on quick On Tee At gt gt disconnect at pressure Lower Port 2 drain port 4640128 AND 4640216 COLOR FLOW VALVES STEP 6 SETTING FLOW CONTROL VALVES Adjust out for faster start response to control Adjust in f
103. ave more than one probable cause and remedy are included This means that problems for which the probable cause and remedy may be immediately obvious are not listed in this section The first rule for troubleshooting and circuit that is hydrau lically operated and electrically controlled is to determine if the circuit is lacking hydraulic oil or electrical control power This can be ascertained by overriding the bypass valve mechanically or electrically so that oil is available to the function valve then overriding the function valve mechanically If the function performs satisfactorily the problem exists with the control circuit 3 3 HYDRAULIC CIRCUIT CHECKS The first reference for improper function of a hydraulic sys tem where the cause is not immediately apparent should be the Troubleshooting Chart The best place to begin the problem analysis is at the power source pump Once it is determined that the pump is serviceable then a system atic control of the circuit components beginning with the control would follow For aid in troubleshooting refer to the illustrated parts manual for hydraulic diagrams of the various circuits Troubleshooting JLG Lift 3 1 SECTION 3 TROUBLESHOOTING TROUBLE Table 3 1 Platform Assembly Troubleshooting PROBABLE CAUSE REMEDY PLATFORM LEVELING SYSTEM Automatic Leveling Inoperative Hydraulic system oil low Dual check valves dirty inoperative Restr
104. carburetor can fully close to idle on load dumps minimiz ing over speeds Examine the system for springs such as carburetor return springs These should be removed Some automotive car buretors as opposed to industrial carburetors contain internal springs for accelerator pumps etc These may make good governing difficult or even impossible For this and other reasons industrial carburetors are pre ferred Move the linkage slowly through its travel and look for any binding or unexplained forces Correct any before going further Many governing problems are really caused by binding of the butterfly and its shaft in the carburetor This is caused by loading due to vacuum under the butterfly and atmospheric pressure above when the engine is running These forces cannot be felt when the engine is not run ning Therefore start the engine while carefully controlling the speed by hand and feel for binding or air load forces Needle bearings on the butterfly shaft are available on many industrial carburetors to deal with this problem Any tendency on the butterfly stick must be corrected Lift 2 23 SECTION 2 PROCEDURES Mounting Controller Select a reasonably cool dry and vibration free location The rear cover will probably need to be removed during set up in order to make adjustments for speed setting and gain You may wish to defer final installation until this is done After completing these adj
105. ce valve Pressure relief valve not functioning properly Re adjust or replace valve Bypass valve dump not functioning Repair or replace valve Lift cylinder not functioning properly Repair or replace cylinder Binding lift cylinder or boom pivot pin Repair or replace cylinder or pin Boom will not lower See Boomwill not raise Pressure relief valve not functioning properly Re adjust or replace valve Holding valve not functioning properly Re adjust or replace valve 3120240 JLG Lift 3 3 SECTION 3 TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY Boom raises and lowers erratically Hydraulic system oil low Restricted or broken supply line on fitting Lack of lubricant on cylinder shafts and or boom pivot Counterbalance valve on lift cylinder improperly adjusted or not functioning properly Control valve not functioning properly Worn seal s in lift cylinder Cylinder notfunctioning properly Replenish oil as necessary Clean repair or replace line or fitting Lubricate as required Refer to Lubrication Chart Replace valve Repair or replace valve Replace seal s Repair or replace cylinder Boom drifts down Worn seal s in lift cylinder Replace seal s Manual lowering valve not functioning properly Repair or replace valve Holding valve on cylinder not functioning properly Repair or replace valve Pump Volume Wheel Motor Speed High Engine Damaged
106. chain adjust block Remove the lifting device from the telescope cylin der Steps 8 9 and 10 apply to 3 Section Boom Only Using a suitable brass drift install the trunnion pins attaching the telescope cylinder to the mid boom section Install the capscrews securing the trunnion pins to each side of the boom Note that loctite 242 is required on the cap screw threads Install trunnion pin covers on each side of boom Steps 11 and 12 apply to 2 Section Boom Only Carefully install the telescope cylinder rod pin through the fly boom Install the capscrews and washers holding the tele scope cylinder rod pin to the fly boom Note that loc tite 242 is required on the capscrew threads Carefully install the telescope cylinder barrel attach pin into base boom Install the setscrews that retain the telescope cylin der pin to the base boom Remove applicable hydraulic line and port caps and correctly connect the hydraulic lines to the tele scope cylinder Ensure all hoses are correctly routed Install boom end cover Activate hydraulic system Using all applicable safety precautions operate the boom functions Check for correct operation and hydraulic leaks Secure as necessary Step 19 applies to 3 Section Boom Only Cycle extend retract boom several times then torque boom chains to 40 ft lbs 2 76 Bar See Section 2 6 Boom Chains for correct torquing proce dure 2 13 SECTION 2 PROCEDURES 20 C
107. cted and the INTERVAL at which the inspection is to take place Under the AREA portion of the table the various systems along with the components that make up that system are listed The INTERVAL portion of the table is divided into five columns representing the various inspec tion time periods The numbers listed within the interval column represent the applicable inspection code for which that component is to be checked The checks and services listed in this schedule are not intended to replace any local or regional regulations that may pertain to this type of equipment nor should the lists be considered as all inclusive Variances in interval times may occur due to climate and or conditions and depend ing on the location and use of the machine JLG Industries requires that a complete annual inspection be performed in accordance with the Annual Machine Inspection Report form Forms are supplied with each new machine and are also available from JLG Customer Service Form must be completed and returned to JLG Industries A IMPORTANT JLG INDUSTRIES REQUIRES THAT A COMPLETE ANNUAL INSPECTION BE PERFORMED IN ACCORDANCE WITH THE ANNUAL MACHINE INSPECTION REPORT FORM NOTE This machine requires periodic safety and mainte nance inspection by a JLG Dealer A decal located on the turntable affords a place to record stamp Inspection dates Notify dealer if Inspection is over due The inspection and maintenance code numbers a
108. d Inspection Replace parts as necessary Apply a coat of grease or petroleum jelly to clus ter gear bore Place sixteen needle rollers into cluster gear bore j Place spacer into opposite side of cluster gear and against needle rollers k Place second set of sixteen needle rollers into cluster gear Apply grease or petroleum jelly to tang side of two thrust washers Place thrust washers against bosses in carrier with washer tang fitting into slot in carrier outside diameter m While keeping thrust washers in place slide cluster gear into carrier with larger gear on side with small pin hole n Line up cluster gear and thrust washers with hole in carrier and slide planet shaft through Ensure chamfered side of hole in planet shaft is lined up with pin hole in carrier Drive anti roll pin flush into carrier hole locking planet shaft into place p Repeat steps h through o for remaining two clus ter gears Input Shaft Assembly A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL AND INSTALLATION a Carefully remove retaining ring 33 from input shaft 32 and discard retaining ring b Remove two spacers 35 and spring 34 from input shaft c Clean and inspect all parts in accordance with paragraph Cleaning and Inspection Replace parts as necessary d Place washer 35 spring 34 and washer 35 in that order onto input shaft e Install retaining ring into input sha
109. e Actuator o Removes ground from the start lock out relay when the engine is running above the start lock out set point A 20 turn pot is provided to adjust this set point usually around 500 RPM h Removes ground from the overspeed relay if this point is exceeded A 20 turn pot is provided to adjust this set point usually around 5000 RPM 4 Pin Connector Pin 2 24 a Input from the elevation limit switches to allow high engine to operate b Input from the high engine switch c Input for mid engine from one of the following The engine low coolant temperature switch plat form footswitch or a ground control directional switch d Provides ground to lockout start when the engine RPMS exceed the set point Check Out and Initial Start Up Procedures JLG Lift Before proceeding familiarize yourself with the locations of the various adjustment pots Adjustments High engine Mid engine Start lockout Over speed lockout Factory adjust Gain High Engine This adjustment is made by turning the 1 8 brass screw clockwise CW to increase speed and counterclockwise CCW to decrease speed The adjustment range of the high engine pot is 25 turns each turn will change engine speed by about 100 to 200 RPMS This pot is protected by a slip clutch at each end and will not be harmed by mod erate over adjustment However the governor will not function when the pot is past full travel If
110. e engine and allow it to come up to operating temperature Adjust throttle lever stop until engine runs at 2000 RPM Shut down engine Reattach actuator cable to throttle lever making sure that low engine setting remains the same If necessary adjust slide pin to contact low engine limit switch at 2000 RPM Shut down engine b With the aid of an assistant start engine from basket and allow to come up to operating tem perature Disconnect proportional dump valve wire Activate footswitch Turn on HIGH ENGINE switch Hold drive controller in full drive position Adjust slide pin to contact high engine limit switch at 3000 RPM Shut off all switches and controllers Reconnect proportional dump valve wire Actuator cable travel must stop slightly before lever makes contact with throttle lever stop Failure to do so will burn out actuator Early machines are at idle until a function is acti vated Later machines are at idle only at platform without footswitch activated Therefore when setting low engine speed on later machines it will not be necessary to disconnect bang bang dump valve wire or operate a bang bang function Just activate foot switch to get low engine JLG Lift 2 20 THROTTLE CHECKS AND ADJUSTMENTS DEUTZ ENGINE F3L1011 SEE FIGURE 2 11 NOTE Never run fuel tank dry Diesel engines cannot be restarted after running out of fuel until fuel system has been air vented or bled of air See Deutz Inst
111. e is required All slings chains cables etc should be parallel to each other and as near perpendicular as possible to top of part being lifted 5 Should it be necessary to remove a component on an angle keep in mind that the capacity of an eye bolt or similar bracket lessens as the angle between the supporting structure and the component becomes less than 90 degrees 6 part resists removal check to see whether all nuts bolts cables brackets wiring etc have been removed and that no adjacent parts are interfering Component Disassembly and Reassembly When disassembling or reassembling a component com plete the procedural steps in sequence Do not partially disassemble or assemble one part then start on another Always recheck your work to assure that nothing has been overlooked Do not make any adjustments other than those recommended without obtaining proper approval Pressure Fit Parts When assembling pressure fit parts use an anti seize or molybdenum disulfide base compound to lubricate the mating surface Bearings 1 When a bearing is removed cover it to keep out dirt and abrasives Clean bearings in nonflammable cleaning solvent and allow to drip dry Compressed air can be used but do not spin the bearing 2 Discard bearings if the races and balls or rollers are pitted scored or burned 3 If bearing is found to be serviceable apply a light coat of oil and wrap it in cl
112. e speed will not function Boom above horizontal Lower boom Horizontal limit switch out of adjustment High engine solenoid malfunctioning Drive pressure switch malfunctioning Electrical malfunctioning Defective engine governor Adjust limit switch to activate close with boom at horizontal and below Repair or replace solenoid valve Replace pressure switch See proper wiring diagram Repair or replace governor 3120240 JLG Lift 3 17 SECTION 3 TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY High pump volume will not function Boom above horizontal Horizontal limit switch out of adjustment Defective pump section Oil by passing in step valve Electrical malfunction Lower boom Adjust limit switch to activate close with boom at horizontal and below Repair or replace pump section Repair or replace step valve See proper wiring diagram High wheel motor speed will not function Boom above horizontal Horizontal limit switch out of adjustment Two speed drive solenoid valve malfunctioning Lower boom Adjust limit switch to activate close with boom at horizontal and below Repair or replace solenoid valve Drive pressure switch malfunctioning Replace pressure switch Valve orifice plugged Unplug valve orifice Defective drive motor Repair or replace motor Grade too steep Check tractability of machine 3 18 JLG Lift 3
113. e wire or operate a bang bang function Just activate foot switch to get low engine SLIDE PIN 1 SLIDE PIN 2 LOW ENGINE ADJUSTMENT SCREW pismo ADDCO MODULE Figure 2 5 Addco Adjustment Ford 2 15 THROTTLE CHECKS AND PRECISION GOVERNOR ADJUSTMENTS ADDCO SEE FIGURE 2 6 NOTE Never run fuel tank dry Diesel engines cannot be restarted after running out of fuel until fuel system has been air vented or bled of air See Deutz Instruction Manual for procedure Checks Check that anti dieseling solenoid is operating If solenoid is operating an audible click at the carbu retor should be heard when ignition is switched on Check throttle linkage for smooth operation by rotat ing throttle lever by hand to full throttle position then slowly back to idle position feeling closely for stick ing or binding To accomplish this the throttle rod must first be disconnected 3120240 JLG Lift Choke Adjustments NOTE Automatic choke and vacuum pulloff adjustment pro cedure to be made only on a cold engine Make sure choke body and mounting bracket are positioned so that choke rod moves freely with no binding anywhere through its stroke The choke spring should hold the choke plate firmly closed but require only slight finger pressure to open at 70 degrees F 21 28 degrees C Retract pulloff shaft until it bottoms as if under engine vacuum Bend pulloff rod until
114. ean waxed paper Do not 3120240 JLG Lift 2 1 SECTION 2 PROCEDURES unwrap reusable or new bearings until they are ready to install 4 Lubricate new or used serviceable bearings before installation When pressing a bearing into a retainer or bore apply pressure to the outer race If the bear ing is to be installed on a shaft apply pressure to the inner race Gaskets Check that holes in gaskets align with openings in the mating parts If it becomes necessary to hand fabricate a gasket use gasket material or stock of equivalent material and thickness Be sure to cut holes in the right location as blank gaskets can cause serious system damage Bolt Usage and Torque Application 1 Use bolts of proper length A bolt which is too long will bottom before the head is tight against its related part If a bolt is too short there will not be enough thread area to engage and hold the part properly When replacing bolts use only those having the same specifications of the original or one which is equivalent 2 Unless specific torque requirements are given within the text standard torque values should be used on heat treated bolts studs and steel nuts in accor dance with recommended shop practices See Figure 1 1 Hydraulic Lines and Electrical Wiring Clearly mark or tag hydraulic lines and electrical wiring as well as their receptacles when disconnecting or removing them from the unit This
115. earing 18 from shaft 10 10 Press rotary oil seal 22 from housing 19 Inspection 1 Clean all parts thoroughly 2 Closely inspect all parts for excessive wear cracks and chips Replace parts as necessary 3 Discard seals and o rings 4 Closely inspect bearings and bearing contact sur faces Replace as necessary NOTE Bearings may be re used if after thorough inspec 3120240 tion they are found to be in good condition Assembly NOTE DISC 11 Lubricate all seals and o rings with clean hyaraulic oil prior to assembly Clean all parts thoroughly before assembly Press new rotary oil seal 22 into housing 19 Note direction of seal Install new bearing 18 and retaining ring 21 on shaft 10 Insert shaft assembly and retaining ring 17 in hous ing 19 Insert dowel pins 20 spring retainer 16 and springs 14 15 in housing 19 Position new large diameter return plate 13 in hous ing with tab guided by dowel pins 20 until disc rests on springs 14 15 A IMPORTANT 12 AND RETURN PLATE 13 SHOULD REMAIN DRY DUR ING INSTALLATION NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES T 10 11 12 NOTE 13 JLG Lift Place a new friction disc 12 on shaft 10 until it con tacts return plate 13 Add additional new discs 11 and new friction discs 12 as required to complete assembly Install new o ring 5 new back up ring 6 new o ring 8 and new back up ring 9
116. efully drive the tele scope cylinder pin from the base boom Steps 7 8 and 9 apply to 3 Section Boom Only Remove the telescope cylinder trunnion pin covers from each side of the base boom Remove the cap screws securing the trunnion pins from each side of the boom Using a suitable slide hammer remove the trunnion pins attaching the telescope cylinder to the mid boom 3120240 SECTION 2 PROCEDURES NOTE 10 11 12 NOTE 13 14 15 NOTE 16 NOTE 17 NOTE 18 19 NOTE 20 21 Steps 10 and 11 apply to 2 Section Boom Only Remove the capscrews and washers holding the telescope cylinder rod pin to the fly boom Using a suitable brass drift carefully drive the tele scope cylinder pin from the fly boom Attach a suitable sling to the telescope cylinder Support with an overhead crane or other suitable lift ing device Steps 13 14 15 and 16 apply to 3 Section Boom Only Remove the two 2 extension chain adjusting nuts from the eyebolt through the chain adjust assembly Remove the four 4 bolts and lock washers attach ing the chain attach block to the base boom section and remove block Attach a suitable lifting device to the extension chain adjusting eyebolt above the cylinder rod The extension chain will come out of the boom twice as far as the telescope cylinder Using both lifting devices carefully pull the cylinder from the boom assembly
117. ep 16 Torque shoulder bolts to 23 27 ft Ibs 81 36 NM Install bolts 41 in remaining holes Torque bolts to 23 27 ft Ibs 31 36 NM Place coupling 1 into spindle and onto input shaft Fill hub one half full of EPGL 90 lubricant before operation 2 25 TORQUE HUB 4WD SEE FIGURE 2 37 Disassembly 1 Position hub over suitable container and remove drain plugs 12 from unit Allow oil to completely drain then replace drain plugs Remove eight bolts 40 and four shoulder bolts 41 securing cover assembly to hub 24 Remove cover assembly and discard o ring seal 23 Remove top thrust washer 39 from hub Thrust washer may stick inside cover Remove top thrust spacer 38 from input shaft sub assembly Pry ring gear 22 loose from hub and remove it Lift carrier assembly 15 from hub Remove input gear 36 and thrust spacer 37 from input shaft assembly and remove input shaft assem bly from hub Remove input shaft 32 and thrustwasher 16 from hub Thrust washer may stick to bottom of carrier Remove internal gear 15 from hub Using a screwdriver or chisel and hammer straighten out the tang on lockwasher 9 which has been bent into the notch in locknut 10 A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL 11 12 13 14 JLG Lift Using an N 13 locknut wrench tool 1 141863 loosen locknut 10 Remove the locknut 10 from spin dle brake and lockwasher 9 and discard
118. erial Number Plate Turntable Serial Number Stamped Boom Sections Serial Number Stamped Serial Number Stamped Turntable frame On left Hand Side of Machines On Left Hand Side Of Machine Figure 1 3 Serial Number Locations 3120240 JLG Lift 1 11 SECTION 1 SPECIFICATIONS intentional blank page JLG Lift 3120240 SECTION 2 PROCEDURES SECTION 2 PROCEDURES 2 4 GENERAL This section provides information necessary to perform maintenance on the aerial platform Descriptions tech niques and specific procedures are designed to provide the safest and most efficient maintenance for use by per sonnel responsible for ensuring the correct installation and operation of machine components and systems A CAUTION WHEN AN ABNORMAL CONDITION IS NOTED AND PROCEDURES CONTAINED HEREIN DO NOT SPECIFICALLY RELATE TO THE NOTED IRREGULARITY WORK SHOULD BE STOPPED AND TECHNICALLY QUALIFIED GUIDANCE OBTAINED BEFORE WORK IS RESUMED The maintenance procedures included consist of servic ing and component removal and installation disassembly and assembly inspection lubrication and cleaning Infor mation on any special tools or test equipment is also pro vided where applicable 2 2 SERVICING AND MAINTENANCE GUIDELINES General The following information is provided to assist you in the use and application of servicing and maintenance proce dures contained in this chapte
119. ering ovality and for excessive wear and evidence of cor rect lubrication Replace bushing as necessary Inspect sheave chain groove for damage Replace sheave assembly as necessary Inspect sheave attach pin for scoring or other dam age and for evidence of correct lubrication Dress pin surface with Scotch Brite or equivalent or replace pin as necessary Inspect sheave pin lubrication drilling and fitting for blockage or the presence of dirt or other foreign material Repair as necessary Assembly NOTE Prior to cylinder assembly ensure that the proper cylinder seal kit is used See your JLG Parts Manual Apply a light film of hydraulic oil to all components prior to assembly A IMPORTANT WHEN INSTALLING POLY PAK PISTON SEALS ENSURE SEALS ARE INSTALLED PROPERLY REFER TO FIGURE 2 3 FOR COR RECT SEAL ORIENTATION IMPROPER SEAL INSTALLATION COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLIN DER OPERATION JLG Lift 3120240 SECTION 2 PROCEDURES PISTON REF Figure 2 3 Poly Pak Seal Installation 1 Place new wiper seal and rod seal into the applica ble cylinder head gland grooves 2 Carefully install the head gland on the rod ensuring that the wiper and rod seals are not damaged or dis lodged Push the head along the rod to the rod end as applicable 3 Carefully slide the piston spacer on the rod If appli cable align the oil holes in the rod and the spacer
120. essure Settings Machines Built from 1995 To Present Sheet 2 of 2 2 56 2 30 Extend A Reach Valve Pressure and Speed Settings Model 40 6 2 57 2 31 Racine Proportional Air Gap Adjustment Machines Built Prior To Mid 1987 2 58 2 32 Swing Bearing Tolerance Boom Placement 2 59 2 33 Swing Bolt Feeler Gauge 2 59 2 34 Swing Bearing Tolerance Measuring 1 2 61 2 35 Swing Bearing Torquing 2 63 2 36 Torque Hub Assembly 2 WD isses n mh 2 64 2 97 Torque Hub 4 WD elei sea cL eva dedos 2 68 2 38 Torque Hub Carrier Timing 2 70 2 39 Swing Brake Assembly Mico Machines Built Prior To May 1992 2 71 2 40 Drive Brake Assembly Mico Machines Built Prior To May 1992 2 73 2 41 Swing Brake Assembly Ausco Machines Built Prior to May 1992 2 76 2 42 Drive Brake machines Built Prior to 1992 2 78 2 43 Drive Brake Mico Machines Built From May 1992 To Machine S N 33476 2 80 2 44 Swing Brake Mico Machines Built From May 1992 To Machine
121. etting low engine speed on later machines it will not be necessary to disconnect bang bang dump valve wire or operate a bang bang function Just activate foot switch to get low engine If the engine hunts or surges in the maximum speed no load condition shut off engine Disconnect car buretor throttle link from governor arm Turn carbu retor throttle link clockwise one turn Start engine and activate HIGH ENGINE as in step 2 Be sure to disconnect proportional dump valve wire If surging continues repeat step 3 Do not turn car buretor throttle link in any further than necessary or governor performance will be affected When surging is under control check HIGH ENGINE RPM If necessary reset to 2400 RPM as in step 2 Shut down engine 2 33 SECTION 2 PROCEDURES 2 CARB IDLE SCREW CARB THROTTLE LINK SPRING LJ 0000005000004500ofl EST a s iom E GOVERNOR 2 34 Figure 2 9 Addco Actuator Adjustments VG4D JLG Lift 3120240 SECTION 2 PROCEDURES 2 19 THROTTLE CHECKS AND ADJUSTMENTS DEUTZ F3L912 ENGINE SEE FIGURE 2 10 NOTE NOTE 3120240 Never run fuel tank dry Diesel engines cannot be restarted after running out of fuel until fuel system has been air vented or bled of air See Deutz Instruction Manual for procedure a Disconnect actuator cable from throttle lever With the aid of an assistant start th
122. from end cover 2 4 Remove o ring 5 back up ring 6 o ring 8 and back up ring 9 from piston 7 5 Remove separators 13 from housing 21 6 Remove stack assembly consisting of shaft 11 return plate 14 and friction discs 12 from housing 21 7 Remove dowel pins 20 springs 15 16 and spring retainer 17 from housing 21 8 Remove retaining ring 18 from housing 21 9 Remove shaft by pressing or using a soft mallet on male end of shaft 10 10 Remove retaining ring 22 and bearing 19 from shaft 10 11 Press rotary oil seal 23 from housing 21 Inspection Clean all parts thoroughly 1 Closely inspect all parts for excessive wear cracks and chips Replace parts as necessary 2 Discard seals and o rings 3 Closely inspect bearings and bearing contact sur faces Replace as necessary NOTE Bearings may be re used if after thorough inspec tion they are found to be in good condition Assembly 3120240 NOTE Lubricate all seals and o rings with clean hydraulic oil prior to assembly 1 Clean all parts thoroughly before assembly 2 Press new rotary oil seal 23 into housing 21 Note direction of seal 3 Install new bearing 19 and retaining ring 22 on shaft 10 4 Insert shaft assembly and retaining ring 18 in hous ing 21 5 Insert dowel pins 20 spring retainer 17 and springs 15 16 in housing 21 6 Position new large diameter return plate 14 in hous ing with tab guided by dowel
123. ft 12 Rotor Bleeder Screw Seal Case O Ring Back Up Ring Piston O Ring Back Up Ring 11 Stator 13 Separator 14 Return Plate 15 Springs 16 Springs 17 Spring Guide 18 Retainer Ring 19 Bearing 20 Dowel Pins 21 Housing 22 Retainer Ring 23 Seal Figure 2 44 Swing Brake Mico Machines Built From May 1992 To Machine S N 33476 2 82 JLG Lift 3120240 SECTION 2 PROCEDURES 2 32 DRIVE BRAKE MICO MACHINES BUILT FROM S N 33476 TO PRESENT SEE FIGURE 2 46 Disassembly 1 Remove end cover 2 from housing 19 by removing capscrews 1 A WARNING END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 2000 POUNDS 907 KG THE FOUR CAPSCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE IF A HYDRAULIC PRESS IS AVAILABLE 3000 LBS 1362 KG MAXIMUM THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAP SCREWS Remove case seal 4 from housing 19 then remove bleeder screw 3 from end cover 2 3 Remove piston 7 from end cover 2 4 Remove o ring 5 back up ring 6 0 ring 8 and back up ring 9 from piston 7 5 Remove stack assembly consisting of shaft 10 sta tors 11 return plate 13 and rotors 12 from housing 19 6 Remove dowel pins 20 springs 14 15 and spring retainer 16 from housing 19 7 Remove retaining ring 17 from housing 19 8 Remove shaft by pressing or using a soft mallet on male end of shaft 10 9 Remove retaining ring 21 and b
124. ft groove to secure spacers and spring to shaft Assembly 1 JLG Lift 1 Using a suitable press press new bearing cups 3 5 with large inside diameters facing out into hub 7 counterbores Place bearing cone 4 into bearing cup 3 in small end of hub Press new seal 2 into hub counterbore with flat metal side facing in Use a flat object to ensure that seal is pressed evenly and is flush with hub face Lower hub onto spindle 1 with large open end up 2 69 SECTION 2 PROCEDURES POSITION PUNCH MARKS AT 12 O CLOCK FOR CORRECT TIMING Figure 2 38 Torque Hub Carrier Timing Place bearing cone 6 over end of spindle and into bearing cup 5 Place tongued washer 8 over end of spindle and against bearing cone A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING INSTALLATION 7 10 Install new lockwasher 9 on top of tongued washer 8 Insert the tab on lockwasher 9 into the slot in spin dle brake 1 Apply loctite 277 to the second screw thread from the bottom of locknut 10 The bottom of the locknut 10 has a chamfered or sloped edge Place locknut 10 onto spindle brake 1 Use an N 13 locknut wrench tool no T 141863 to tighten the locknut Using a torque wrench and the locknut wrench apply 50 ft lbs 68 NM of torque to locknut 10 then 13 14 15 16 17 18 19 rotate the hub in both clockwise and counterclock 20 wise directions
125. he turntable bearing or frame mounted com ponents Carefully place the turntable on a suitably supported trestle Use a suitable tool to scribe a line on the outer race of the swing bearing and the frame This line will aid in aligning the bear ing upon installation Remove the bolts and washers which attach the outer race of the bearing to the frame Discard the bolts Use suitable lifting equipment to remove the bearing from the frame move the bearing to a clean suitably supported work area 3120240 SECTION 2 PROCEDURES MEASURING POINT SWING BEARING FRAME REF Figure 2 34 Swing Bearing Tolerance Measuring Point Installation NOTE A thru M only apply to machines built prior to mid of 1991 NOTE Manufacturing tolerances of frames and turntables are inspected prior to the factory installation of swing bearings to determine the need for use of Devcon filler When servicing machine swing bearing apply Devcon filler only to those machines having Devcon previously applied at the factory If new turntable or frame is being installed contact manufacturer for procedures to determine the need for Devcon appli cation a 3120240 Use suitable standard tools and equipment to carefully remove any hardened epoxy residue from the bearing mounting area of frame and turntable Apply a layer of Devcon or equivalent filler approximately 0 125 inches 0 318 cm thick on the bearing mounting p
126. he pin in place with attaching hardware Remove boom prop and overhead crane Activate hydraulic system Using all applicable safety precautions operate the boom functions Check for correct operation and hydraulic leaks Secure as necessary Check fluid level of hydraulic tank and adjust as nec essary 2 11 BOOM MAINTENANCE Removal 2 14 NOTE Remove the platform from boom assembly Remove the slave leveling cylinder from boom assembly Boom Assembly weighs approximately Two Section Boom 1795 Ibs 814 kg Three Section Boom 2275 Ibs 1032 kg Using suitable lifting equipment adequately support boom weight along entire length of retracted boom A CAUTION HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM 4 11 12 Tag and disconnect hydraulic lines that run along the side of the boom Remove hardware attaching upper lift cylinder attach pin to boom Using a slide hammer or similar tool and taking care not to damage pin remove pin from boom Using all applicable safety precautions and only if necessary operate crane and fully retract lift cylin der Shut down machine systems Tag and disconnect all wiring to ground control box Loosen and remove hardware securing boom pivot pin Ensuring that boom is adequately supported and using a suitable slide hammer carefully remove pivot pin from b
127. heck fluid level of hydraulic tank and adjust as nec essary Boom Lift Cylinder Removal 1 Place the machine on a flat and level surface Start the engine and place the boom in a horizontal posi tion Shut down the engine and prop the boom See Figure 2 2 Remove the hardware retaining the cylinder rod attach pin to the boom Using a suitable brass drift drive out the cylinder rod attach pin Using auxiliary power retract the lift cylinder rod completely Disconnect cap and tag the boom lift cylinder hydraulic lines and ports Remove barrel end attach pin retaining hardware Using a suitable brass drift drive out the barrel end attach pin from the turntable upright Remove the cylinder from the boom and place in a suitable work area Boom Lift Cylinder Installation 1 Install lift cylinder in place using suitable slings or supports aligning attach pin mounting holes on the turntable upright Using a suitable drift drive the barrel end attach pin through the mounting holes in the lift cylinder and the turntable upright Secure in place with the pin retaining hardware Remove cylinder port plugs and hydraulic line caps and correctly attach lines to cylinder ports Using auxiliary power extend the cylinder rod until the attach pin hole aligns with those in the boom Using a suitable drift drive the cylinder rod attach pin through the aligned holes taking care to align the grooved pin holes Secure t
128. icted or broken hydraulic line or fitting on slave oylinder or lift cylinder Spit valve s leaking Worn seal s in slave level or lift cylinder Counterbalance valves in slave cylinder defective Slave level or lift cylinder not functioning properly Replenish oil as necessary Clean or replace as necessary Clean repair or replace line or fitting Clean repair or replace spit valve s Replace seal s Replace counterbalance valve Repair or replace cylinder Platform Will Not Maintain Level Attitude Counterbalance valve on slave leveling cylinder improperly adjusted or not functioning properly Worn seal s in slave level or lift cylinder Damaged slave level or lift cylinder Replace valve Replace seal s Repair or replace cylinder No Response To Platform Leveling Controls Level control inoperative Hydraulic system oil low System orifice plugged dirty Restricted or broken hydraulic line or fitting Repair or replace control valve Replenish oil as necessary Clean orifice Clean repair or replace line or fitting Control valve not functioning properly Repair or replace valve No electric to dump or control valve See proper wiring diagram Slave cylinder not functioning properly Repair or replace pump Platform Will Not Adjust Up To Level Hydraulic pump not functioning properly Repair or replace pump Restricted or broken hydraulic line or fitting Slave cylinder
129. idle start engine and allow engine to come up to operating temperature Set idle speed at 1000 RPM using idle adjustment screw on carbu retor Shut off engine 2 20 JLG Lift Remove cover on Addco actuator With no function activated actuator should be fully extended Hold governor arm in idle position Adjust slide pin 1 to contact idle limit switch at output rod end of actua tor Adjust actuator rod until you can hook up to gov ernor arm With the aid of an assistant start engine from basket and allow to come to operating temperature Dis connect proportional dump valve wire Activate foot Switch Turn high engine switch on Hold drive controller in full drive position Adjust slide pin 2 to contact high engine limit switch at 2400 RPM Shut off all switches and controllers Reconnect propor tional dump valve wire 3120240 SECTION 2 PROCEDURES With the aid of a assistant start engine from basket and allow to come to operating temperature Dis connect bang bang dump valve wire Activate foot Switch Operate a bang bang function switch to increase RPM to low engine Using a small screw driver set low engine at 1800 RPM at the Addco electronic module NOTE Early machines are at idle until a function is acti vated Later machines are at idle only at platform without footswitch activated Therefore when setting low engine speed on later machines it will not be necessary to disconnect bang bang dump valv
130. ier for damage especially in anti roll pin and planet shaft hole areas 6 Inspect all planet shafts for scoring or other dam age 7 Inspect all threaded components for damage includ ing stretching thread deformation or twisting 8 Inspect seal mounting area in hub for burrs or sharp edges Dress applicable surfaces or replace compo nents as necessary 9 Inspect cover for cracks or other damage and o ring sealing area for burrs or sharp edges Dress applicable surfaces or replace cover as necessary JLG Lift 2 63 SECTION 2 PROCEDURES Coupling Spindle Seal Bearing Cone Bearing Cup Wheel Boit Pipe Plug Hub Bearing Cup Bearing Cone Spacer Retaining Ring Internal Gear Shatt Spacer Spring Retaining Ring Thrust Washer Spacer Input Gear Spacer Carrler Shaft Roll Pin Thrust Washer Needle Roller Spacer Cluster Gear O Ring Ring Gear Thruat Washer Cover O Ring Cover Cap O Ring Disconnect Rod Disconnect Cap Bolt Pipe Plug Bolt Shoulder Bolt Flatwasher Figure 2 36 Torque Hub Assembly 2 WD 2 64 JLG Lift 3120240 SECTION 2 PROCEDURES Repair 1 3120240 Cover Assembly a Remove two bolts 38 securing disconnect cap 87 to cover 32 and remove cap b Remove two bolts 38 securing cover cap 34 to cover and remove cap c
131. ift Down 3 While monitoring pressure gauge adjust reducing cartridge to 600 PSI 41 Bar plus 50 PSI 3 4 Bar 4 Remove pressure gauge Figure 2 19 Vickers Proportional Valve Pressure Setting Machines Built Prior To 1989 With Accessory Valve Sheet 2 of 4 2 46 JLG Lift 3120240 SECTION 2 PROCEDURES Lift Down Adjust 1200 PSI 82 7 Bar A Side Lift Up Adjust 2500 PSI 172 38 Bar 150 PSI 0 B Side Drive Adjust 3000 PSI 206 8 Bar Swing Adjust 1100 PSI 75 85 Bar Install gauge at quick disconnect on tee lower port VICKERS Note All Pressure Plus or Minus 150 PSI 10 34 Bar Except Where Noted STEP 3 Swing Adjust Right and Left Monitor gauge at quick disconnect on rellef valve Lock turntable and activate Swing Right Add shims to increase pressure remove shims to decrease pressure Same procedure applies to Swing Left Lift Adjust Lift Down Monitor gauge at quick disconnect on relief valve Bottom out Lift Down Add shims to increase pressure remove shims to decrease pressure Lift Up Bottom out Lift Up add shims to increase pressure remove shims to decrease pressure Drive Adjust Disconnect and cap brake line at counterbalance valve also plug port in valve Have assistant activate Drive Forward Monitor gauge at quick disconnect on rellef valve Add shims to increase pressure remove shims to decrease pressure Same procedure applies t
132. ine Crankcase Wisconsin VG4D w Filter 5 0 quarts 4 73 L NOTE Tolerance on all engine rpm settings is plus or minus 10 1 2 COMPONENT DATA Engine Ford LSG423 Lrg423 3120240 Oil capacity 5 quarts 4 73 L w Filter 4 quarts 3 79 L w o Filter Cooling System 16 quarts 15 14 L Low RPM 1000 no load Mid RPM 1800 no load High RPM 3000 no load Alternator 40 Amp belt drive Battery 1000 cold cranking Amps 210 min utes reserve capacity 12 VDC Fuel Consumption Low RPM 2 03 GPH 7 68 LPH Fuel Consumption High RPM 2 73 GPH 10 33 LPH Horsepower 63 2800 RPM no load Engine Ford LRG 425 0 1 Oil Capacity 4 50 Quarts 4 25 1 w Filter 3 50 Quarts 3 31 1 w o Filter Idle RPM 1000 Low RPM 1800 High RPM 2800 Alternator 95 Amp Belt Drive Battery 1000 Cold Cranking Amps 210 minute reserve Capacity 12 VDC Fuel Consumption Low RPM 3 45 GPH 13 06 Iph High RPM 4 60 GPH 17 41 Iph Horsepower 74 3000 RPM full load Cooling System 16 Quarts 15 14 Engine Deutz F3L912 Oil capacity 9 5 quarts 8 99L w Filter 8 5 quarts 8 04 L w o Filter Low RPM 1800 High RPM 2400 Alternator 85 Amp belt drive Battery 1000 cold cranking Amps 210 minutes reserve capacity 12VDC Fuel Consumption Low RPM 2 03 GPH 7 68 LPH Fuel Consumption High RPM 2 73 GPH 10 33 LPH Horsepower 47 2800 RPM
133. ing Replace switch Repairor replace solenoid Replace circuit breaker Adjust repair or replace horizontal limit switch Reduce load Rebuild engine Time engine Replace filter Replace fuel line Repair or replace governor Engine surges Governor not adjusted properly Correctly adjust governor JLG Lift 3120240 SECTION 3 TROUBLESHOOTING TROUBLE Table 3 4 Chassis Assembly Troubleshooting PROBABLE CAUSE REMEDY CONTROL VALVES Valve spool sticking Dirtin oil causing excessive temperature build up Incorrect valve mounting causing warping of the unit Valve spool scored Return spring weak or broken Relief valve malfunctioning causing excessive pressure within valve Change oil using recommended viscosity and flush System Loosen valve and check mounting Repair as nec essary Remove valve and repair or replace as necessary Remove valve and repair or replace as necessary Check pressure delivery to and from valve and repair or replace as necessary Valve leaking Dirtor other foreign material under seal Valve spool scored Excessive back pressure caused by restricted return line to reservoir Damaged valve seal s Remove and repair valve as necessary Repair or replace valve Remove line and clean obstruction or replace line as necessary Repair or replace valve as necessary FUEL SYSTEM Strong fuel odor du
134. ing air to escape from top port Pressure should not exceed 100 psi 6 9 Bar during bleeding 3 Apply sufficient pressure to release brake and check for proper operation 2 27 DRIVE BRAKE MICO MACHINES BUILT PRIOR TO MAY 1992 SEE FIGURE 2 40 Disassembly 1 Remove end cover 29 from housing 50 by removing capscrews 26 and lockwashers 27 A WARNING END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 1500 POUNDS 681 KG THE FOUR CAPSCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE IF A HYDRAULIC PRESS IS AVAILABLE 3000 LBS 1362 KG MAXIMUM THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAP SCREWS AND LOCKWASHERS bearing 32 from cover 3120240 SECTION 2 PROCEDURES 3 Remove o ring 31 square ring 30 pipe plug 28 and bleeder screw 38 from end cover 4 Remove piston 35 from end cover by inserting two 1 4 20 UNC bolts into threaded holes in piston By turning and pulling piston can be removed from bore 5 Remove o ring 33 back up ring 34 o ring 36 and back up ring 37 from piston 35 6 Remove separators 43 from housing 50 7 Remove shaft assembly consisting of shaft 39 discs 40 44 friction discs 42 springs 41 and bearings 32 48 from housing by pressing or using a soft mal let on male end of shaft 8 Remove springs 41 from between tabs of discs 40 44 9 Remove bearings 32 48 from shaft using an appro priate bearing puller The discs and friction discs will then s
135. inkage geome try for most installations A 70 degrees Spring loaded to idle Engine at idle C Engine at max Note that the angle between the carburetor arm and the rod is 70 degrees with the engine at idle This is very desir able Note also that the Actuator arm travels equally on either side of a 90 degree angle with the rod This angular arrangement will give the proper mechanical gain for good stability and performance It may be necessary to rotate the carburetor arm relative to the butterfly to achieve this This can usually be done and is usually worth the effort Below are some workable installations with good linkages Remember the Actuator can be turned 180 degrees on its mounting to reverse the spring loaded direction Also the Actuator can be Mounted in any attitude 70 degrees QW Spring loaded to idle Engine at idle D Engine at max 70 degrees Spring loaded to idle 2 Engine at idle Engine at max The needed travel of the carburetor determines how far out the Actuator arm the rod is to be attached Inmost cases The carburetor should be moved from closed to above 10 degrees from full open as the Actuator is moved min to max THEN ALTER THE LENGTH OF THE ROD SLIGHTLY PERHAPS 030 SO THAT THE ACTUATOR IS JUST OFF ITS INTERNAL STOP AND IS PULLING THE BUTTER FLY AGAINST ITS STOP This insures that the
136. ional Valve Pressure Setting Machines Built To Present Sheet 4 of 4 2 44 2 18 X Vickers Proportional Valve Pressure Setting Machines Built Prior 1989 With Accessory Valve Sheet 1 014 2 45 2 19 X Vickers Proportional Valve Pressure Setting Machines Built Prior To 1989 With Accessory Valve Sheet 2 of 4 2 46 2 20 Vickers Proportional Valve Pressure Setting Machines Built Prior To 1989 With Accessory Valve Sheet 3 4 2 47 2 21 Vickers Proportional Valve Pressure Setting Machines Built Prior To 1989 With Accessary Valve Sheet 4 4 2 48 2 22 Solenoid Valve Pressure Settings Machines Built Prior To 1992 With Steering Wheel 2 49 2 23 Pressure And Flow Settings Machines Built Prior May 1992 With Steering Wheel 2 50 2 24 All Hydraulic Machines Pressure Settings Sheet 1014 2 51 ii JLG Lift 3120240 TABLE OF CONTENTS 2 25 Vickers All Hydraulic Machines Pressure Settings Sheet 2014 2 52 2 26 Vickers All Hydraulic Machines Pressure Settings Sheet 3 4 2 53 2 27 Vickers All Hydraulic Machines Pressure Settings Sheet 4 4 2 54 2 28 Solenoid Valve Pressure Settings Machines Built Before 1995 Sheet 1 of 2 2 55 2 29 Solenoid Valve Pr
137. is also avoided by relieving cir cuit pressure The relief valve is installed in the circuit between the pump outlet pressure line and the cylinder of the circuit generally as an integral part of the system valve bank Relief pressures are set slightly higher than the load requirement with the valve diverting excess pump delivery back to the reservoir when operating pres sure of the component is reached Relief Valves Crossover relief valves are used in circuits where the actu ator requires an operating pressure lower than that sup plied to the system When the circuit is activated and the required pressure at the actuator is developed the cross over relief diverts excess pump flow to the reservoir indi vidual integral reliefs are provided for each side of the circuits 2 6 BOOM CHAINS SEE FIGURE 2 1 Adjusting Procedures A WARNING ENSURE MACHINE IS ON A FIRM AND LEVEL SURFACE 1 Fully retract boom in the horizontal position 2 Torque fly boom retract chains adjust to 28 ft Ibs 38 NM 3 Torque fly boom extend chains adjust to 28 ft Ibs 38 NM 4 Cycle boom extend at least three feet and return to the fully retracted position 5 Recheck fly boom retract chains 28 ft lbs 88 NM required 6 Recheck fly boom extend chains 28 ft 16 38 NM required 7 Repeat steps 2 3 and 4 if necessary 8 Check for proper operation of boom JLG Industries Inc requires a comple
138. late on the frame Use suitable lifting equipment to carefully lower the swing bearing into position on the frame Ensure that the scribed line of the outer race of the bearing aligns with the scribed mark on the frame If a new swing bearing is used ensure that the filler plug fitting is at 90 degrees from the fore and aft centerline of the frame Ensure that all frame and bearing attachment holes are aligned and install four diametrically opposed bolts or clamps to secure the bearing to the frame Tighten the bolts or clamps evenly in a diametrically opposed pattern to a torque of 20 ft Ibs 2 77 kgm e Allow Devcon filler to cure at room temperature approximately 70 degrees F 21 degrees C for 10 to 16 hours f After the appropriate interval release the clamps or remove the bolts Use a suitable lifting device to carefully remove the bearing from the frame g Carefully remove any excess filler from the frame mounting area from the bearing attachment holes and from between the gear teeth A WARNING ENSURE THAT TURNTABLE IS ADEQUATELY SUPPORTED WHILE APPLYING DEVCON AND WHILE INSTALLING THE BEARING EXTREME CARE MUST BE TAKEN DURING THE FOLLOWING STEPS TO AVOID SERIOUS OR FATAL INJURY TO PERSONNEL h Apply a layer of Devcon or equivalent filler approximately 0 125 inches 0 318 cm thick to the underside of the bearing mounting area of the turntable base plate i Use suitable hydraulic jacks to carefu
139. le brass drift to remove pin Remove sheave assembly Remove the bolts washers and bar from the trun nion pins which secure the cylinder base to the boom mid section use a suitable slide hammer to remove the pins A CAUTION WHEN REMOVING THE TELESCOPE CYLINDER FROM THE BOOM IT MAY BE NECESSARY AT SOME POINT TO TURN THE CYLINDER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED WITHIN THE BOOM CARE MUST BE TAKEN TO MOVE THE CYLINDER SLOWLY FROM THE BOOM DAMAGE TO COM PONENTS MAY RESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES 13 14 15 NOTE 16 17 18 19 NOTE 20 21 JLG Lift Pull the cylinder partially from the rear of the boom mid section secure the cylinder with a suitable sling and lifting device at approximately the center of gravity Carefully remove the telescope cylinder and sheave assembly Place the cylinder on a suitable trestle Remove bolts and washers from the sheave pin remove the pin and the sheave assembly Steps 16 thru 19 apply to 2 Section Boom Only Remove bolts and washers from the pin securing telescope cylinder to fly boom use a brass drift to remove the pin Pull the cylinder partially from the rear of the boom mid section secure the cylinder with a suitable sling and lifting device at approximately the center of gravity Using suitable lifting equipment carefully slide the fly section from the base section Place the fly sec tions on a sui
140. lide off either end of shaft 10 Remove dowel pins 47 springs 45 46 and oil seal 49 from housing 50 Inspection 1 Clean all parts thoroughly 2 Closely inspect all parts for excessive wear cracks and chips Replace parts as necessary 3 Discard seals and o rings 4 Closely inspect bearings and bearing contact sur faces Replace as necessary NOTE Bearings may be re used if after thorough inspec tion they are found to be in good condition Figure 2 40 Drive Brake Assembly Mico Machines Built Prior To May 1992 Assembly NOTE Lubricate all seals and o rings with clean hydraulic oil prior to assembly 1 Insert new oil seal 49 dowel pins 47 and springs 45 46 in housing 50 2 Install new bearing 48 on male end of shaft 39 and press until it shoulders on shaft 3120240 3 Insert shaft and bearing on housing 50 and press until bearing bottoms on shoulder in housing 4 Position large diameter disc 44 in housing with tabs guided by dowel pins 47 until disc rests on springs 45 46 A IMPORTANT DISC 15 19 AND FRICTION DISCS 17 SHOULD REMAIN DRY DUR ING INSTALLATION NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES JLG Lift 2 73 SECTION 2 PROCEDURES 10 11 NOTE 2 74 Place friction disc 42 on shaft until it contacts bottom disc 44 Insert one spring 41 on each dowel pin 47 Add additional discs 40 friction discs 42 and spring
141. linder 2 8 2 3 Poly Pak Seal 1 2 11 2 4 Governor Adjustment Ford with 2 20 2 5 Addco Adjustment E Ord ERR C REA 2 21 2 6 Precision Governor Adjustment Ford Sheet 1 2 2 30 2 7 Precision governor Adjustment Ford Sheet 2012 2 31 2 8 Addco Actuator Adjustments 21511 2 32 2 9 Addco Actuator Adjustments 2 1 2 34 2 10 Addco Actuator Adjustments 31912 1 2 36 2 11 Addco Actuator Adjustments 11011 2 37 2 12 X Racine Proportional Valve Pressure Setting Machines Built Prior To Mid 1987 Sheet 1 of 2 2 39 2 13 Racine Proportional Valve Setting Machines Built Prior To Mid 1967 Sheet 2 of 2 2 40 2 14 Proportional Valve Pressure Setting Machines Built To Present Sheet 1 of 4 2 41 2 15 Vickers Proportional Valve Pressure Setting Machines Built To Present Sheet2 of 4 2 42 2 16 X Vickers Proportional Valve Pressure Setting Machines Built To Present Sheet 3 Of 4 2 43 2 17 Vickers Proport
142. linder head inside diameter for scoring or other damage and for ovality and tapering Replace as necessary Inspect seal and o ring grooves in head for burrs and sharp edges Dress applicable surfaces as nec essary If applicable inspect cylinder head retainer or end cap for surface or thread damage Repair or replace as necessary 11 12 13 14 15 16 17 18 NOTE 19 20 21 22 Inspect cylinder head outside diameter for scoring or other damage and ovality and tapering Replace as necessary If applicable inspect thread ring for scoring or other damage Dress threads or applicable surfaces as necessary If applicable inspect seal grooves in thread ring for burrs and sharp edges Dress applicable surfaces as necessary If applicable inspect rod and barrel bushings for signs of correct lubrication and excessive wear Replace as necessary Inspect travel limiting collar or spacer for burrs and sharp edges If necessary dress inside diameter surface with Scotch Brite or equivalent If applicable inspect port block fittings and holding valve Replace as necessary Inspect the oil ports for blockage or the presence of dirt or other foreign material Repair as necessary If applicable inspect piston rings for cracks or other damage Replace as necessary Steps 19 through 22 apply to the 3 Section Boom telescope cylinder only Inspect chain sheave bushings for scoring tap
143. lly raise the swing bearing to the underside of the turntable mounting plate Ensure that the scribed line of the inner race of the bearing aligns with the scribed mark on the turntable if a new swing bearing is used ensure that the filler plug fitting is at 90 degrees from the fore and aft centerline of the turntable j Ensure that all turntable and bearing attachment holes are aligned and install four diametrically opposed clamps or bolts and nuts to secure the JLG Lift 2 61 SECTION 2 PROCEDURES bearing to the turntable Tighten the nuts and bolts or clamp evenly in a diametrical pattern to a torque of 20 ft Ibs 2 78 kgm k Allow Devcon filler to cure at room temperature approximately 70 degrees F 21 degrees C for 10 to 16 hours After the appropriate time interval place a suit able hydraulic jack under the bearing and release the clamps or remove the nuts and bolts use the hydraulic jack to carefully remove the bearing from the turntable m Carefully remove excess filler from the turntable mounting area from the bearing attachment holes and from between gear teeth n Position the bearing on the machine frame in the same position as noted in step c above A CAUTION JLG INDUSTRIES RECOMMENDS THAT ALL REMOVED BEARING NUTS AND BOLTS BE DISCARDED AND REPLACED WITH NEW NUTS AND BOLTS SINCE THE SWING BEARING IS THE ONLY STRUCTURAL LINK BETWEEN THE FRAME AND TURNTABLE IT IS IMPERATIVE THA
144. n 2 34 M 1 4 TORQUE REQUIREMENTS Description Torque Inter Value Dry val Hours A Bearing To Chas 110 Ibs 200 500 sis 149 Nm B Bearing To Turn 220 Ibs 200 500 table 298 Nm C Wheel Lugs 90 Ibs 100 122 Nm D Drive Hub 150 Ibs 200 500 204 Nm E Swing Hub 110 Ibs 200 500 149 Nm NOTE Retorque after first 200 hours of operation and every 500 hours thereafter NOTE See Procedure Section for tightening sequence of turntable bearing bolts NOTE When maintenance becomes necessary or a fas tener has loosened refer to the Torque Chart to determine proper torque value 1 5 LUBRICATION Ford LSG423 LRG423 LRG425 Engine Single Viscosity Oils SF SF SE SF CC SF CD When Outside Temp is Use SAE Consistently Viscosity Number JLG Lift 1 3 SECTION 1 SPECIFICATIONS 10 F 60 24 C to 16 C 10 F 90 F 12 C to 32 Above 32 F 0 C Above 50 F 10 C 10W 20W 20 30 40 Multi Viscosity Oils SF SF SE SF CC SF CD When Outside Temp is Consistently Below 10 F 12 C Below 60 F 16 C 10 F 90 F 23 to 32 C gt Above 10 F 23 C Above 20 F 23 C Use SAE Viscosity Number 5W 20 5W 30 10W 30 10W 40 or 10W 50 20W 40 or 20W 50 Not recommended for severe service including high RPM operation Deutz F3L912 F3L1011 Engine Wiscon
145. n controller Defective pump low oil volume Repair or replace drive motor s Properly adjust engine speed Replace pressure regulator if necessary Replace switch Correctly adjust controller Repair or replace pump Poor response function shuts off slowly when command is removed Low spool spring preload Sticking spool due to contamination Ramp set too high in controller Sticking control handle Check for correct spring and shimsin end cap Remove end cap and check spool freedom Adjust controller Repair or replace controller 3120240 JLG Lift 3 11 SECTION 3 TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY STEERING SYSTEM No response to control Circuit breaker open Determine and correct cause reset circuit breaker If equipped steer tow selector in tow position Hydraulic system oil low Hydraulic system pressure too low Damaged wiring on control switch or solenoid valve Control switch not functioning properly Restricted or broken hydraulic line on valve bank hydraulic pump or rotary coupling Swivel coupling leaking internally Seal s defec tive Control valve not functioning properly Steer cylinder not functioning properly Actuate control to steer position Valve knob in Replenish oil as necessary Adjust pressure See proper wiring diagram Replace switch Clean repair or replace line Repair or replace coupling
146. ng Diagram Standard Deutz 21511 131912 4 Engine W Hydraulic Controls Sheet 1 2 3 28 3 10 Wiring Diagram Standard Deutz F21511 f31912 amp Wisconsin Engine W Hydraulic Controls Sheet 2 2 3 29 3 11 Wiring Diagram Standard Deutz 11011 Engine W Standard Controls Sheet 1 Of 2 3 30 3 12 Wiring Diagram Standard Deutz 1011 Engine W Standard Controls Sheet 2 Of 2 3 31 3 13 Wiring Diagram Standard Deutz 11011 Engine W Hydraulic Controls Sheet 1 Of 2 3 32 3 14 Wiring Diagram Standard Deutz 11011 Engine W Hydraulic Controls Sheet 2 Of 2 3 83 3 15 Wiring Diagram Standard Lrg425 Dis Engine W Standard Controls Sheet 1 Of 2 3 34 3 16 Wiring Diagram Standard Lrg425 Dis Engine W Standard Controls Sheet 2 Of 2 3 35 3 17 Wiring Diagram Standard Ford Dis Engine W Hydraulic Controls Sheet 1 Of 2 3 36 3 18 Wiring Diagram Standard Ford Dis Engine W Hydraulic Controls Sheet 2 Of 2 3 37 LIST OF TABLES TABLE NO TITLE PAGE NO 2 1 Chain Stretch Tolerance 1 tee panos e dap Ee Ut RC ERI Gor 2 7 2 2 Cylinder Piston Nut Torque 2 12 2 3 Holding Valve Torque 1 4 2 12 2 4
147. ng or loose replace missing or loose bolts with new bolts and torque to the value specified in the torque chart after lubricating the bolt threads with loctite 271 After replacing and retorquing bolt or bolts recheck all existing bolts for looseness 1 Check the frame to bearing attach bolts as follows a Fully elevate the retracted boom b Atthe position indicated on a of Figure 2 32 try to insert a 0015 feeler gauge between the bolt and hardened washer at the arrow indicated position c Ensure that the 0015 feeler gauge will not pene trate under the bolt head to the bolt shank d Swing the turntable 90 degrees and check some selected bolts at the new position 3120240 e Continue rotating the turntable at 90 degrees intervals until a sampling of bolts have been checked in all quadrants 2 Check the turntable to bearing Attach bolts as fol lows a Fully extend boom at horizontal b Atthe position indicated on b of Figure 2 32 try to insert the 0015 feeler gauge between the bolt head and hardened washer at the arrow indi cated position At the position indicated on Figure 2 33 try and insert the 0015 feeler gauge between the bolt head and hard ened washer at the arrow indicated position 0015 Feeler Gauge Figure 2 33 Swing Bolt Feeler Gauge Check JLG Lift 2 59 SECTION 2 PROCEDURES Wear Tolerance 1 From the underside of the machine at rear center
148. ntally assisted failure Two conditions must be present corrosive agent and static stress In the chain static stress is present at the aperture due to the press fit pin ARC LIKE CRACKED PLATES STRESS CORROSION No cycle motion is required and the plates can crack during idle periods The reactions of many chemical agents such as battery acid fumes with hardened metals liberate hydrogen which attacks and weakens the metal grain structure Chain Anchors Sheaves and Pins An inspec tion of the chain must include a close examination of chain anchors sheaves and pins Check chain anchors for wear breakage and misalignment Anchors with worn or broken fingers should be replaced They should also be adjusted to elimi nate twisting the chain for an even load distribu tion Sheaves should be inspected for worn flanges which would indicate misalignment and wear on the outside diameter of the sheave A worn sheave can mean several problems as follows 1 Chains too tight 2 Sheave bearings pin bad 3 Bent misaligned chains 2 7 WEAR PADS 1 JLG Lift Shim up wear pads within 1 16 in 1 59 mm toler ance between wear pad and adjacent surface Replace wear pads when worn within 1 8 in 3 18 mm of threaded insert 3120240 SECTION 2 PROCEDURES Table 2 1 Chain Stretch Tolerance Chain Pin To Pin Allowable Size Measurement Stretch 0 50 in 1 2
149. o Drive Reverse Figure 2 20 Vickers Proportional Valve Pressure Setting Machines Built Prior To 1989 With Accessory Valve Sheet 3 Of 4 3120240 JLG Lift 2 47 SECTION 2 PROCEDURES STEP 4 To Set Main Relief Proportional Functions Note This adjustment to be made after all proportional func tions are set Adjust Disconnect and cap hoses to drive motor also plug ports on drive section of proportional valve Back out adjust ment 2 turns counter clockwise Have assistant activate drive Slowly turn adjustment In clockwise and watch pressure gauge Continue turning until gauge stops mov Ing approximately 3000 PSI 206 8 Bar Turn adjustment In and additional 1 2 turn this will result In approximately 200 PSI 13 8 Bar higher than Drive rellef setting VICKERS Install gauge at quick disconnect VALVE on tee lower port Figure 2 21 Vickers Proportional Valve Pressure Setting Machines Built Prior To 1989 With Accessary Valve Sheet 4 Of 4 2 48 JLG Lift 3120240 SECTION 2 PROCEDURES TELE IN amp OUT ADJUSTMENT 1 Engine Low RPM 2 2 Section Boom Bottom out tele in adjust to 2000 PSI 137 9 Bar CHECK POINT FOR TELE 3 3 Section Boom Bottom out tele in adjust to 2500 PSI ROTATE AND MAIN RELIEF 172 4 Bar 4 Bottom out tele out adjust to 1500 PSI 103 4 Bar MAIN RELIEF ADJUSTMENT 1 Engine Low RPM 2 Bottom out tele
150. ockwash ers and nuts which secure the powertrack to car rier tube d Ensure all hoses and cables are properly routed through the carrier tube and powertrack Tighten or install all clamping or securing apparatus to the hoses or cables as necessary 3120240 SECTION 2 PROCEDURES Installation 1 Using suitable lifting equipment position assembled boom on turntable so that boom pivot holes in both boom and turntable are aligned 2 Insert boom pivot pin ensuring that locating slots in pin are aligned with setscrew locating holes in pin bushings 3 If necessary gently tap pin into position with a soft headed mallet Secure pin with setscrews 4 Connectall wiring to ground control box 5 Using all applicable safety precautions operate lift ing equipment in order to position boom lift cylinder so that holes in cylinder rod end and boom structure are aligned Insert lift cylinder pin 6 If necessary gently tap pin into position with a soft headed mallet ensuring that pin plate holes are aligned with attach holes in boom structure Install pin attaching bolts washers and lockwashers 7 Shutdown machine systems 8 Connecthydraulic lines running along side of boom 9 Using all applicable safety precautions operate machine systems and raise and extend boom fully noting the performance of the extension cycle If chattering is apparent extend chain system requires adjustment 10 Retract and lower bo
151. oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stability for mobile hydraulic system ser vice JLG Industries recommends Mobilfluid 424 hyaraulic oil which has an SAE viscosity of 10W 30 and viscosity index of 152 When temperatures remain consistently below 4 20 E 7 C an amount of no 2 diesel fuel not to exceed 20 of system capacity may be added to the hydraulic oil reservoir This diesel fuel will thin the hydraulic oil for easier cold weather operation and will almost completely dissipate from the hydrau lic system over a several month period of time When cold weather is past it may be necessary to drain and refill the hydraulic system to rid the system of any remaining diesel fuel Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities If use of hydraulic oil other than Kendall Hyken 052 is desired or Mobilfluid 424 contact JLG Industries for proper recommendations 3120240 SECTION 1 SPECIFICATIONS 8 J3avao avs 9 AVS Figure 1 1 Torque Chart 1 5 JLG Lift
152. om noting performance of retraction cycle If chattering is apparent retract chain system requires adjustment 11 Shutdown machine systems 12 Adjust extend and retract chain systems as required and secure adjustment recounts 13 As necessary lubricate all points requiring lubrica tion 2 12 TILT ALARM SWITCH NOTE There are two methods of adjustment a manual adjustment and an adjustment using a voltmeter A CAUTION PERFORM TILT ALARM SWITCH LEVELING PROCEDURE A MINI MUM OF EVERY SIX MONTHS TO ENSURE PROPER OPERATION AND ADJUSTMENT OF SWITCH Manual Adjustment 1 Park the machine on a flat level surface Ensure machine is level and tires are filled to rated pressure 3120240 NOTE Ensure switch mounting bracket is level and securely attached 2 Level the base of the indicator by tightening the three flange nuts through approximately one half of its spring travel DO NOT ADJUST THE X NUT DURING THE REMAINDER OF THE PROCEDURE 3 With the electrical connections complete slowly tighten one of the Y nuts until the circuit is closed and the light on the Platform Control Console illumi nates 4 Slowly back off the nut counting the number of turns until the circuit is again closed and the light again illuminates 5 Divide the number of turns determined in step d in half Tighten the nut this many turns The line deter mined by this nut and the X nut is now parallel to the ground 6
153. on piston 7 Note order of o rings and back up rings Insert piston 7 into end cover 2 being careful not to shear o rings or back up rings Install new case seal 4 in housing 19 then install bleeder screw 3 in end cover 2 Position end cover 2 on housing 19 aligning dowel pins 20 with holes in end cover Install capscrews 1 and tighten evenly to draw end cover 2 to housing 19 Torque capscrews to 55 ft Ibs 75 NM If available a hydraulic press will simplify installation of end cover on housing Clamp cover in position while tightening the capscrews If hydrostatic bench testing is performed on the brake assembly release pressure should not exceed 2000 psi 137 Bar unless two additional bolts are used for supplemental clamping 2 83 SECTION 2 PROCEDURES Bolts Cover Bleeder Screw Seal Case O Ring Back Up Ring Piston O Ring Back Up Ring 10 Shaft 11 Stator 12 Rotor 13 Return Plate 14 Springs 15 Springs 16 Spring Guide 17 Retainer Ring 18 Bearing 19 Housing 20 Pins Dowel 21 Retalner Ring 22 Seal Cil 23 O Ring 24 Gasket 25 Plug Pipe Figure 2 45 Drive Brake Mico Machines Built From S N 33476 To Present 3120240 SECTION 2 PROCEDURES 2 33 SWING BRAKE MICO MACHINES BUILT FROM S N 33476 TO PRESENT SEE FIGURE 2 46 Disassembly 14 Remove end cover 2 from housing 19 by removing capscrews 1 A WARNING
154. oom and turntable structure Ensure that boom and turntable structure are not damaged Carefully lift boom assembly clear of turntable and lower to ground or suitably supported work surface Disassembly A CAUTION HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF CONTAMINANTS INTO SYSTEM 1 NOTE 2 JLG Lift Remove hydraulic lines electrical cables carrier tube power track from right side of boom assembly Step 2 applies to 3 Section Boom Only Remove the telescope cylinder extension chain assembly 3120240 SECTION 2 PROCEDURES NOTE NOTE NOTE 3120240 Remove control console from the platform Remove platform from fly boom assembly Remove carrier tube and power track from right side of the boom assembly Steps 6 and 7 apply to 3 Section Boom Only Removal and disassemble of the extension chain attachment and adjustment assembly mounted at aft of boom base section as follows a Remove jam nut and nut which secures the chain attachment clevis bolt to the chain adjust ment block b Remove the bolts and washer which secure the extension chain attachment assembly to the base boom section remove chain attachment assembly from the base boom section mounting point c Remove the cotter pins from the clevis pins Remove clevis pins and washers from the chain attachment clevis bolt remove the chain attach ment cle
155. or slower start response to control Figure 2 27 Vickers All Hydraulic Machines Pressure Settings Sheet 4 of 4 2 54 JLG Lift 3120240 SECTION 2 PROCEDURES TELE IN amp OUT ADJUSTMENT CHECK POINT FOR 1 Engine Low RPM ROTATE AND MAIN RELIEF 2 Bottom Out Tele in Adjust to 2500 PSI 172 4 Bar 3 Bottom Out Tele Out Adjust to 2000 PSI 137 9 Bar MAIN RELIEF ADJUSTMENT 1 Engine Low RPM 2 Bottom Out Rotate or Basket Level 3 Adjust to 2750 PSI 189 7 Bar STEER LEFT AND STEER RIGHT ADJUSTMENT Note The 4 stack racine valve 4640247 is with rotate 1 Engine Low RPM 2 Bottom Out Steer Left Adjust to 2000 PSI 137 9 Bar 3 Bottom Out Steer Right Adjust to 2000 PSI 137 9 Bar Figure 2 28 Solenoid Valve Pressure Settings Machines Built Before 1995 Sheet 1 of 2 3120240 JLG Lift 2 55 SECTION 2 PROCEDURES STEER LEFT AND STEER RIGHT ADJUSTMENT 1 Engine 2 Low RPM 2 Bottom Out Steer Left Adjust to 2000 PSI 137 9 Bar 3 Bottom Out Steer Right Adjust to 2000 PSI 137 9 Bar CHECK POINT FOR TELE ROTATE AND MAIN RELIEF TELE IN amp OUT ADJUSTMENT 1 Engine Low RPM 2 Bottom Out Tele In Adjust to 2500 PSI 172 4 Bar 3 Bottom Out Tele Out Adjust to 2000 PSI 137 9 Bar Note The 4 stack racine valve MAIN RELIEF ADJUSTMENT 4640940 is with rotate 1 Engine Low RPM
156. ormally not have to be adjusted Normally startout should occur at around 500 RPM If while crank ing the engine seems to stop momentarily then reengages the starter turn the adjustment in CW 1 4 to 1 2 turn at a time until the engine will crank with out locking out start If the starter engages while the engine is running check the idle RPMS before adjusting the governor On the 800 series this should be 1000 RPMS Do not set the RPMS above 1100 RPMS as this will cause engine shut down problems that will be similar to dieseling Over speed This adjustment is made by turning the 1 8 brass screw clockwise CW to increase speed and counterclockwise CCW to decrease speed The adjustment range of the Over speed pot is about 25 turns each turn will change engine speed about 100 to 200 RPMS This pot is pro tected by a slip clutch at each end and will not be harmed by moderate over adjustment However the governor will not function when the pot is past full travel If you suspect that you have over adjusted the Over speed pot or have lost track of where you are turn the pot 25 turns in CW then turn out CCW 5 1 2 turns This will get you back into the range you should be in Over speed should normally not have to be adjusted When adjusting Over speed make sure other adjustments have been made correct Factory This adjustment is made by turning the plastic screw clockwise CW to increase governor sensitivity counter clockwise
157. ort is provided A WARNING SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON TROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER OPER ATOR A B HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures Every effort should be made to relieve any system pres sure prior to disconnecting or removing any portion of the system Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on to direct any line pressure back into the reservoir Pressure 3120240 feed lines to system components can then be disconnected with minimal fluid loss A C MAINTENANCE A WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION NO SMOKING IS MANDATORY NEVER REFUEL DUR ING ELECTRICAL STORMS ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES REMOVE ALL RINGS WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE DO NOT WEAR LONG HAIR UNRESTRAINED OR LOOSE FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT OBSERVE AND OBEY ALL WARNINGS AND CAU TIONS ON MACHINE AND IN SERVICEMANUAL KEEP OIL GREASE WATER ETC WIPED FROM STANDING SURFACES AND HAND HOLDS USE CAUTION WHEN CHECKING A HOT PRESSUR IZED C
158. ot e With the engine running at low speed move the Governor arm throughout its stroke by hand You should feel a constant smooth force in the on direction No binding or rubbing should be felt within the Governor If steps 1a thru 1e can be accomplished as described the Governor is probably OK It recognizes underspeed overspeed onspeed and is not binding internally If the above steps cannot be accomplished satisfactorily there is probably an actual Governor malfunction a Governor is unable to move fuel system freely not enough Actuator force available If Gover nor doesn t move fuel system to on far enough 3120240 SECTION 2 PROCEDURES to provide sufficient fuel but Governor arm moves far enough when disconnected look for 1 Linkage binding or misadjusted 2 Low voltage at Governor during operation NOTE Measure the voltage as discussed previously and observe voltage during operation If Governor fails to move full on and voltage dips over 1 volt check for undersize wire should be 16 minimum 3 Excessive force at Governor during engine running particularly on carbureted engines NOTE Carburetor butterfly valves are loaded by engine vacuum during running which can add considerable force not present when engine isn t running At 70 F the choke plate should be open 1 3 not touching the choke bore If the ambient temperature is not 70 F an additional adjustment is required a
159. ound to be in good condition Assembly NOTE Lubricate all seals and o rings with clean hyaraulic oil prior to assembly Clean all parts thoroughly before assembly Press new rotary oil seal 23 into housing 21 Note direction of seal Install new bearing 19 and retaining ring 22 on shaft 10 Insert shaft assembly and retaining ring 18 in hous ing 21 Insert dowel pins 20 spring retainer 17 and springs 15 16 in housing 21 Position new large diameter return plate 14 in hous ing with tab guided by dowel pins 20 until disc rests on springs 15 16 A IMPORTANT DISC 15 19 AND FRICTION DISCS 17 SHOULD REMAIN DRY DUR ING INSTALLATION NO OIL RESIDUE SHOULD BE ALLOWED TO CONTAMINATE DISC SURFACES 7 11 12 13 NOTE 14 JLG Lift Place a new friction disc 12 on shaft 10 until it con tacts return plate 14 Add additional new discs 11 and new friction discs 12 as required to complete assembly Insert separators 13 in holes of return plate 14 Install new o ring 5 new back up ring 6 new o ring 8 and new back up ring 9 on piston 7 Note order of o rings and back up rings Insert piston 7 into end cover 2 being careful not to shear o rings or back up rings Install new case seal 4 in housing 21 then install bleeder screw 3 in end cover 2 Position end cover 2 on housing 21 aligning dowel pins 20 with holes in end cover Install capscrews 1 and tighten evenly to draw end cover 2
160. out Tele In 2 Monitor gauge at quick disconnect 3wing Adjust Right and Left 3 E sid CW to increase pres 1 Lock turntable Monitor gauge at quick discon 4 Early machines add shims to increase pres nect sure remove shims to decrease 2 Turn adjustment screw CW to increase pres sure CCw to decrease Early machines add Tele Adjust Tele Out shims to increase pressure remove shims to decrease 1 Bottom out Tele Out 3 Activate Swing Right 2 Monitor gauge at quick disconnect 4 Same procedure applies to Swing Left 3 Turn adjustment screw CW to increase pres sure CCw to decrease Early machines add ift Adjust Lift Down shims to increase pressure remove shims to decrease 1 Bottom out Lift Down 2 Monitor gauge at quick disconnect 3 Turn adjustment screw CW to increase pres sure CCw to decrease Early machines add shims to increase pressure remove shims to decrease Figure 2 25 Vickers All Hydraulic Machines Pressure Settings Sheet 2 of 4 2 52 JLG Lift 3120240 SECTION 2 PROCEDURES MAIN RELIEF ADJUST PRESSURE REDUCING ADJUST SEQUENCE ADJUST 4640716 p Accessory Valve Assembly STEP 4 SETTING MAIN RELIEF PROPORTIONAL FUNCTIONS Note This adjustment to be made after all proportional functions are set 1 Disconnect and cap hoses to brakes and cap port at counterbalance valve 2 Back out adjustment 2 turns counterclockwise 3 Have assistant activ
161. out installation NOTE Step 22 apply to 2 Section Boom Only SECTION 2 PROCEDURES 22 23 24 25 26 NOTE 27 28 29 30 31 2 18 Align the cylinder rod end attachment holes with the boom fly section attachment holes install the pin and secure the pin by installing washers and bolts Align the cylinder base end attachment holes with the boom mid section attachment holes install the trunnion pins and secure the pins by installing bars washers and bolts Slide the mid section into the base section Allow the retraction chains to trail between the bottom sur faces of boom sections ensure that no twists exist in chains Shim the top of the mid section for a total of 1 16 inch 062 clearance Install wear pads into the forward portion of the base section Shim boom if necessary for a total of 2 10 inch 20 clearance Assemble the extension chain attachment and adjustment assembly mounted at aft of boom base section as follows a Align the attaching holes of the chain attach ment clevis bolt with those of the extension chain end install the clevis pin through the attaching holes Install the washer and cotter pin which secures the clevis pin through the chain attachment assembly Step 27 applies to 2 Section Boom Only Align the cylinder base end attachment point with those of the boom base section If necessary use an auxiliary hydraulic power source to extend and retr
162. ove pressure gauge Figure 2 24 Vickers All Hydraulic Machines Pressure Settings Sheet 1 of 4 3120240 JLG Lift 2 51 SECTION 2 PROCEDURES Adjust Lift Down 1100 PSI 75 85 Bar Adjust Tele In 2500 PSI 172 4 Bar Adjust Lift Up 2500 PSI 172 4 Bar Adjust Tele Out 2000 PSI 137 9 Bar Adjust Drive 3000 PSI 206 8 Bar Install Pressure Gauge At Quick Disconnect On Tee At Lower Port Adjust Swing 1200 PSI 82 74 Bar 4640918 Control Valve Assembly Vickers 4 Section STEP 3 SETTING DRIVE SWING LIFT AND TELE ADJUSTMENTS FTER BRAKE LINES ARE DISCONNECTED AND PRIOR TO MAKING ADJUSTMENTS ACTIVATE WITH NO PERSONNEL IN VICINITY OF TRAVEL PATH TO ENSURE BRAKES ARE HOLDING drive Adjust Lift Adjust Lift Up 1 Disconnect and cap brake line at counterbal 1 Bottom out Lift Up ance valve also plug port in valve 2 Monitor gauge at quick disconnect 2 Have assistant activate Drive Forward 3 Turn adjustment screw CW to increase pres 3 Monitor gauge Turn adjustment screw CW to sure CCw to decrease increase pressure CCw to decrease Early 4 Early machines add shims to increase pres machines add shims to increase pressure re sure remove shims to decrease move shims to decrease 4 Same procedure applies to Drive Reverse Tele Adjust Tele In Make note of pressures Leave brake line capped until all adjustments are complete 1 Bottom
163. ove shims to decrease Same to Swing Left Lift Adjust Lift Down Monitor gauge at quick connect on rellef valve Bottom out Lift Down Turn adjustment screw CW to increase pressure CCW to decrease pressure Early Machines add shims to increase pressure remove shims to decrease Lift Up Bottom out Lift Up turn adjustment screw CW to increase pressure CCW to decrease pressure Early Machines add shims to increase pressure remove shims to decrease Drive Adjust Disconnect and cap hose to drive motor aiso plug port in valve Have assistant activate drive forward Monitor gauge at quick connect on rellef valve Turn adjustment screw CW to increase pressure CCW to decrease pressure Early Machines add shims to increase pressure remove shims to decrease RELIEF VALVE Install Pressure Gauge At Quick Discon nect PROPORTIONAL VALVE ADJUST STEP 3 Figure 2 16 Vickers Proportional Valve Pressure Setting Machines Built To Present Sheet 3 Of 4 3120240 JLG Lift 2 43 SECTION 2 PROCEDURES RELIEF VALVE 4640522 J Install Pressure Gauge At Quick Discon nect Note This adjustment to be made after all propor tional functlons are set Disconnect and cap hose to brake line at counterbalance valve also plug port in valve Back out adjustment 2 turns counter clockwise Have assis tant activate drive Slowly turn adjustment in clockwise and watch pressure ga
164. oved during disassembly Measure the inside dimensions of the base and mid sections to determine the number of shims required for proper lift Step 2 applies to 2 Section Boom Only 3120240 SECTION 2 PROCEDURES NOTE NOTE 10 11 12 13 3120240 Measure the inside dimensions of the base section to determine the number of shims required for proper lift Install side wear pads to the aft end of the fly sec tion shim evenly to the measurements of the inside of the mid section Step 4 applies to 2 Section Boom Only Install side wear pads to the aft end of the fly sec tion shim evenly to the measurements of the inside of the base section Install the side wear pads to the aft end of the mid section shim evenly to the measurement of the inside of the base section Shim the insides of the boom sections for a total of 1 16 inch 062 clearance if the action is centered there will be 1 32 clearance on each side Steps 7 and 8 apply to 2 Section Boom Only Slide fly section into the base section a distance of approximately one foot measurement of the inside of the base section top wear pad clearance and fab ricate shim packs Remove the fly section from the base section and install two top wear pads and a shim pack Shim the top of the fly section for a total of 1 16 inch 062 clearance Slide fly section into the mid section a distance of approximately one foot measurement of the in
165. peratures below 15 F is not recommended If it is necessary to start the system in a sub zero environment it will be necessary to heat the oil with a low density 100VAC heater to a minimum temperature of 15 F 7 The only exception to the above is to drain and fill the system with Mobil DTE 11 oil or its equivalent This will allow start up at temperatures down to 20 F However use of this oil will give poor perfor mance at temperatures above 120 F Systems using DTE 11 oil should not be operated at temperatures above 200 F under any condition Changing Hydraulic Oil 8 Use of any of the recommended crankcase or hydraulic oils eliminates the need for changing the oil on a regular basis However filter elements must be changed after the first 40 hours of operation and every 250 hours thereafter If it is necessary to change the oil use only those oils meeting or exceeding the specifications appearing in this man ual If unable to obtain the same type of oil supplied with the machine consult local supplier for assis tance in selecting the proper equivalent Avoid mix ing petroleum and synthetic base oils JLG Industries recommends changing the hydraulic oil annually 9 Use every precaution to keep the hydraulic oil clean If the oil must be poured from the original container into another be sure to clean all possible contami nants from the service container Always clean the mesh element of the filter and replace
166. r Safety and Workmanship Your safety and that of others is the first consideration when engaging in the maintenance of equipment Always be conscious of weight Never attempt to move heavy parts without the aid of a mechanical device Do not allow heavy objects to rest in an unstable position When raising a portion of the equipment ensure that adequate support is provided Cleanliness 1 The most important single item in preserving the long service life of a machine is to keep dirt and for eign materials out of the vital components Precau tions have been taken to safeguard against this Shields covers seals and filters are provided to keep air fuel and oil supplies clean however these items must be maintained on a scheduled basis in order to function properly 2 At any time when air fuel or oil lines are discon nected clear adjacent areas as well as the openings and fittings themselves As soon as a line or compo nent is disconnected cap or cover all openings to prevent entry of foreign matter 3 Clean and inspect all parts during servicing or main tenance and assure that all passages and openings are unobstructed Cover all parts to keep them clean Be sure all parts are clean before they are installed New parts should remain in their contain ers until they are ready to be used Components Removal and Installation 4 Use adjustable lifting devices whenever possible if mechanical assistanc
167. r Low sequence pressure Low pilot pressure Wrong defective spool in drive section Low voltage in electrical system Reset valve as required Repair or replace pump section or pump Clean repair or replace valve Check system oil for contamination Drain system and replace with recommended oil Refer to Hydraulic Oils Repair or replace component line or fitting Replace valve replace cylinder Correctly adjust controller Reset valve as required Reset valve as required Repair or replace drive section Correct low voltage problem System s operate erratically Sticking or binding valve spool pistons rods etc Clean repair or replace components as required AUXILIARY HYDRAULIC SYSTEM Auxiliary hydraulic pump inoperable Circuit breaker open Check valve in system leaking Battery requires charging or will nothold charge Damaged wiringoncontrol switch or auxiliary pump Control switch not functioning properly Restricted or broken hydraulic line or fitting Pump motor solenoid not functioning properly Pump motor notfunctioning properly Low pilot pressure Determine and correct cause reset circuit breaker Repair or replace valve Charge or replace battery as required See proper wiring diagram Replace switch Clean repair or replace line or fitting Replace solenoid Repair or replace motor Reset valve as required 3120240 JLG Lift
168. r the piston will be forced in the opposite direction and the cyl inder rod will retract Holding valves are used in the Lift Telescope Slave Level and lockout circuits to prevent retraction of the cylinder rod should a hydraulic line rupture or a leak develop between the cylinder and its related control valve 2 5 VALVES THEORY OF OPERATION Solenoid Control Valves Bang Bang Control valves used are four way three position solenoid valves of the sliding spool design When a circuit is acti vated and the control valve solenoid energizes the spool is shifted and the corresponding work port opens to per mit oil flow to the component in the selected circuit with the opposite work port opening to reservoir Once the cir cuit is deactivated control returned to neutral the valve spool returns to neutral center and oil flow is then directed through the valve body and returns to reservoir A typical control valve consist of the valve body sliding spool and two solenoid assemblies The spool is machine fitted in the bore of the valve body Lands on the spool divide the bore into various chambers which when the spool is shifted align with corresponding ports in the valve body open to common flow At the same time other ports would be blocked to flow The spool is spring loaded to center position therefore when the control is released the spool automatically returns to neutral prohibiting any flow through the circuit
169. r between frame slabs through which the cam valve wheel protrudes Remove cap from fitting on cam valve and connect your hose see 1 above at this point Attach the other end of the hose to the quick con nect on the swing brake Using a floor jack or overhead crane raise one front wheel approximately 6 inches 15 2 cm off the ground Use a bar as a lever to press down on the cam valve plunger which will allow the axle to fully oscillate against the stop With the aid of an assistant start the engine from ground control A WARNING ENSURE TURNTABLE LOCK IS ENGAGED 9 3120240 While your assistant activates swing from ground control depress plunger on cam valve and open both bleeders on the lockout cylinder of the elevated wheel purging any air 10 11 12 13 Remove the jack from the elevated wheel and using the bar again press down on the cam valve plunger allowing the axle to center Next raise the other front wheel as you did in step 6 and repeat steps 7 thru 10 Shut down the engine remove the hose and replace the cap on the cam valve fitting Install frame cover over cam valve and disengage turntable lock The boom can now be returned to its normal posi tion Lockout Cylinder Bleeding With Holding Valves A IMPORTANT ENSURE PLATFORM IS FULLY LOWERED AND BOOM IS CEN TERED OVER REAR AXLE PRIOR TO BEGINNING BLEEDING PROCEDURE MAKING SURE MACHINE IS ON A LEVEL SURFACE AND RE
170. r normal conditions for machines used in multi shift opera tions and or exposed to hostile environments or conditions lubrication frequencies must be increased accordingly 3120240 Figure 1 2 Lubrication Chart Sheet 2 of 2 JLG Lift 1 7 SECTION 1 SPECIFICATIONS Lubrication Specifications Solenoid Valve Table 1 2 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 degrees F Excellent water resistance and adhesive qualities and being of extreme pressure type Timken OK 40 pounds minimum Extreme Pressure Gear Lube oil meeting API Service Classification GL 5 or Mil Spec Mil L 2105 Hydraulic Oil API Service Classification GL 8 SAE 10W 20 Viscosity Index 152 e g Kendall Hyken 052 or Mobilfluid 424 Engine crankcase Oil Gas API SF SG class MIL L 2104 Diesel API CC CD class MIL L 2104B MIL L 2104C EPGL HO EO NOTE Refer to Lubrication Chart Figure 1 2 for specific lubrication procedures Main Relief 2500 psi 172 38 Bar Telescope In a 2 Section Boom 2000 psi 137 9 Bar b 3 Section Boom 2500 psi 172 38 Bar Telescope Out 1500 psi 103 43 Bar Rotate 2500 psi 172 38 Bar Level Up 2500 psi 172 38 Bar Level Down 1500 psi 103 43 Bar Steer a Without Wheel 1500 psi 103 43 Bar b Without Wheel 2500 psi 172 3
171. re as fol lows 1 2 3 4 10 11 12 13 14 15 16 Check for proper and secure installation Check for visible damage and legibility Check for proper fluid level Check for any structural damage cracked or broken welds bent or warped surfaces Check for leakage Check for presence of excessive dirt or foreign material Check for proper operation and freedom of move ment Check for excessive wear or damage Check for proper tightness and adjustment Drain clean and refill Check for proper operation while engine is running Check for proper lubrication Check for evidence of scratches nicks or rust and for straightness of rod Check for condition of element replace as neces sary Check for proper inflation Clean or replace suction screen To Be Performed Quarterly Inspection and Maintenance Code 10 to be performed every two years Axle Lockout Test to be performed quarterly Inspection and Maintenance Code 8 to be performed every two years 2 90 JLG Lift 3120240 SECTION 2 PROCEDURES Table 2 4 Preventive Maintenance and Inspection Schedule AREA INTERVAL BOOM DAILY WEEKLY MONTHLY 3 MONTH 6 MONTH YEARLY 1 Platform 1 4
172. rel Using suitable protection clamp the cylinder rod in a vise or similar holding fixture as close to the piston as possible Remove the set screw s if applicable and nut which attach the piston to the rod and remove the piston Discard self locking set screws Remove the piston rings Remove and discard the piston o rings seal rings and backup rings Remove the set screw if applicable piston spacer and wear ring if applicable from the rod Remove the rod from the holding fixture Remove the cylinder head gland and retainer if applicable Discard the o rings back up rings rod seals and wiper seals Cleaning and Inspection 1 10 2 10 Clean all parts thoroughly in an approved cleaning solvent Inspect the cylinder rod for scoring tapering ovality or other damage If necessary dress rod with Scotch Brite or equivalent Replace rod if necessary Inspect threaded portion of rod for excessive dam age Dress threads as necessary Inspect inner surface of cylinder barrel tube for scor ing or other damage Check inside diameter for tapering or ovality Replace if necessary Inspect threaded portion of barrel for damage Dress threads as necessary Inspect piston surface for damage and scoring and for distortion Dress piston surface or replace piston as necessary Inspect seal and o ring grooves in piston for burrs and sharp edges Dress applicable surfaces as nec essary Inspect cy
173. replace the chain This type of problem is accelerated by poor lubrication maintenance practice and most tight joint chains have been operated with little or no lubrication Tight joints on leaf chain are generally caused by 1 Bent pins or plates 2 Rusty joints 3 Peened plate edges Oil rusty chains and replace chains with bent or peened chain components Keep chains lubri cated TIGHT JOINTS s SP se Protruding or Turned Pins Chains operating with inadequate lube generate tremendous fric tion between the pin and plates pin and bushing on roller chain In extreme cases this frictional torque can actually turn the pins in the outside press fit plates Inspect for turned pins which can be easily spotted as the V flats on the pin heads are no longer in line Replace all chains showing evidence of turned or protruding pins Keep chains lubricated Stress Corrosion Cracking The outside link plates which are heavily press fitted to the pins are particularly susceptible to stress corrosion cracking Like fatigue cracks these initiate at the point of highest stress aperture but tend to extend in an arc like path often parallel to the roll ing grain of the material ABNORMAL PROTRUSION OR TURNED PINS o o Also more then one crack can often appear on a link plate In addition to rusting this condition can be caused by exposure to an acidic or caustic medium or atmosphere Stress corrosion is an environme
174. ring machine operation Fuel tank overfilled Fuel tank damaged Fuel from tank damaged Filter or carburetor fuel leak Check fuel tank and immediately wipe up any spilled fuel Drain all fuel from tank and remove tank for replace ment or repair Replace fuel line Determine cause of leak and make appropriate repairs FRONT FRAME AXLE AREA One or both front wheels will not steer Steering link or tie rod broken or attaching hardware missing Replace steering link tie rod or hardware as neces sary One or both front wheels will not rotate or rotate erratically Wheel hub or bearings damaged or not lubricated Hub attachment nut loose or missing Replace hub or bearings as necessary and repack bearings with approved grease Secure or replace hub attachment nut and cotter pin as necessary Oscillating Axle will not hold properly Air in oscillating axle hydraulic system Cam Valve Stuck or leaking Lockout cylinder leaking See bleeding procedure in section 2 Repair or replace cam valve Repair or replace cylinder 3120240 JLG Lift 3 9 SECTION 3 TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY REAR FRAME AXLE AREA Difficulty encountered when moving machine Loadcapacity exceeded Reduce load Apply loads only in accordance with load capacity indicator Flow divider sticking Repair or replace flow divider Machine being moved up
175. rked tooth will be located just under carrier on upper two gears With shoulder side of ring gear 30 facing down place ring gear over into mesh with large gears Ensure punch marks remain in correct location dur ing ring gear installation Install input gear 20 into carrier meshing with small diameter cluster gears 28 Counterbore in bore of input gear must be to outside of carrier assembly Turn over carrier assembly and ring gear while keep ing gears in mesh Place thrust washer 18 into car rier counterbore Use petroleum jelly or grease to hold washer in place While holding ring gear input gear and cluster gears in mesh place small side of cluster gears into mesh with internal gear On ring gear locate hole marked X over one of counterbored holes in hub Mark counterbored holes on outside diameter for later use If gears do not mesh easily or carrier assembly does not rotate freely then remove carrier and ring gear and check cluster gear timing Slide thrust spacer 21 over end of input shaft Place thrust washer 31 into carrier counterbore Place o ring 29 into cover assembly counterbore Use petroleum jelly or grease to hold o ring in place Pace cover assembly over ring gear with oil level check plug in cover located approximately 90 degrees from oil fill plug in hub 21 22 23 24 Locate four shoulder bolts 41 and flat washers 42 90 degrees apart into counterbored holes in hub marked in st
176. rn gain P2 adjusting screw CCW until surging ceases Turn high engine P1 adjusting screw until engine runs at 2400 RPM Turning the screw CW increases RPM Turning the screw CCW decreases RPM While your assistant continues to depress the foot switch have him place engine speed switch to LOW ENGINE Turn low mid engine adjusting screw until engine runs at 1800 RPM Turning the screw CW increases RPM Turning the screw CCW decreases RPM Shut down engine Seal all trim pots when finished with finger nail polish If engine surges under no load on HIGH ENGINE and you cannot get enough response from adjusting gain P2 try adjusting surge screw on actuator Loosen surge screw locknut Disconnect throttle link age Turn surge screw CW until linkage arm moves Manually stroke the linkage fully and allow to return slowly until it stops Try to move linkage towards return position If linkage moves turn surge screw CCW 1 2 turn Again stroke linkage and allow to return slowly until it stops Try to move linkage towards return position If linkage moves turn surge screw CCW 1 2 turn Repeat this procedure until linkage does not move after stroking Do not turn any more This will set buffer spring tension properly Reconnect throttle linkage With engine speed switch set to LOW ENGINE when footswitch is depressed engine should imme JLG Lift diately respond if response time lags turn gain P2 adjus
177. ruction Manual for procedure a Disconnect actuator cable from throttle lever With the aid of an assistant start the engine and allow it to come up to operating temperature Adjust throttle lever stop until engine runs at 1800 RPM Shut down engine Reattach actuator cable to throttle lever making sure that low engine setting remains the same If necessary adjust slide pin to contact low engine limit switch at 1800 RPM Shut down engine b With the aid of an assistant start engine from basket and allow to come up to operating tem perature Disconnect proportional dump valve wire Activate footswitch Turn on HIGH ENGINE switch Hold drive controller in full drive position Adjust slide pin to contact high engine limit switch at 3000 RPM Shut off all switches and controllers Reconnect proportional dump valve wire NOTE Actuator cable travel must stop slightly before lever makes contact with throttle lever stop Failure to do so will burn out actuator Early machines are at idle until a function is acti vated Later machines are at idle only at platform without footswitch activated Therefore when setting low engine speed on later machines it will not be necessary to disconnect bang bang dump valve wire or operate a bang bang function Just activate foot switch to get low engine 2 35 SECTION 2 PROCEDURES ACTUATOR CABLE ADDCO ACTUATOR ACTUATOR CABLE LOW ENGINE LIMIT SWITCH SLIDE PIN 1 SLID
178. ry Check wiring continuity See proper wiring diagram See correctwiring diagram Replace switch Engine continues to crank Faulty ignition and or starter circuit wiring Malfunctioning starter solenoid or motor Faulty starter switch Check wiring continuity See proper wiring diagram Replace solenoid or motor in accordance with appli cable manufacturer s manual Replace switch INSTRUMENTS AND INDICATORS Travel warning horn inoperative Circuit breaker open Damaged wiring in horn circuit Damaged horn Determine and correct cause reset circuit breaker Repair or replace wiring Replace horn 3 16 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY Hourmeter inoperative Damaged wiring in hourmeter circuit Repairor replace wiring Defective vacuum switch Replace vacuum switch Inoperative hourmeter Replace hourmeter Tilt alarm circuit Damaged wiring in tilt alarm circuit Tiltalarm inoperative Tilt alarm not adjusted properly Repair or replace wiring See proper wiring diagram Replace tiltalarm Re adjusttilt alarm Defective bulb in tilt light Replace bulb Wheel motor speed circuit Switch damaged or inoperative Replace switch Damaged or disconnected wiring circuit See proper wiring diagram Plugged orifice in shifter valve Clean orifice Faulty shifter valve Repair or replace valve High engin
179. s 41 as required to complete assembly Alter nate discs and friction discs during assembly Insert separators 43 over spiral pins in housing When properly installed separators will contact top of bottom disc Install o ring 33 back up ring 34 o ring 36 and back up ring 37 on piston 35 Insert piston into end cover 29 being careful not to shear o rings or back up rings Inserting 1 4 20 UNC bolts in piston may simplify installation Install o ring 31 bearing 32 square ring 30 pipe plug 28 and bleeder screw 38 in end cover Position end cover on housing aligning dowel pins with holes in cover and push end cover until top fric tion disc aligns with spline shaft Install capscrew 26 and lockwashers 27 Tighten evenly to draw end cover to housing and bearing onto shaft Torque capscrews to 55 ft Ibs 75 NM If available a hydraulic press will simplify installation of end cover on housing Clamp cover in position while tightening capscrews 12 To eliminate binding on bearings press on inner ring of bearing 32 until it shoulders on shaft Restrain opposite end of shaft to avoid excessive thrust load ing of bearing 49 A IMPORTANT IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE BRAKE ASSEMBLY RELEASE PRESSURE SHOULD NOT EXCEED 2000 PSI 137 9 BAR UNLESS TWO ADDITIONAL BOLTS ARE USED FOR SUPPLEMENTAL CLAMPING Bleeding 1 2 JLG Lift Install brake and connect pressure lines Bleed press
180. s is dissipated bled Biber 6 With boom over right side of machine place DRIVE control lever to REVERSE and drive machine off of 11 Using a suitable lifting equipment lift front of block and ramp machine remove the 6 in 15 2 cm high block 7 Have an assistant check to see that left front wheel 12 Transfer the 6 in 15 2 cm high block to the left front remains locked in position off of ground Wheel and repeat steps 2 thru 7 substituting the 8 Carefully activate SWING control lever and return word right for left in step 5 boom to stowed position centered between drive i heels After boom reaches stowed position acti 18 Perf llat le lockout test vate DRIVE and lockout cylinders should release and allow wheel to rest on ground 2 36 OSCILLATING AXLE LOCKOUT TEST 9 Place the 6 in 15 2 cm high block with ascension ramp in front of right front wheel A IMPORTANT 10 Place DRIVE control lever to FORWARD and care fully drive machine up ascension ramp until right LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ats er HE EE ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED 11 Carefully activate SWING control lever and position boom over left side of machine NOTE Ensure BOO Te retracted lowered aud 12 With boom over left side of machine place DRIVE tered between drive wheels prior to beginning lock out cylinder te
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182. side of the mid section top wear pad clearance and fabri cate shim packs Remove the fly section from the mid section and install two top wear pads and a shim pack Shim the top of the fly section for a total of 1 16 inch 062 clearance Slide the mid section into the base section a dis tance of approximately one foot measurement top wear pad clearance and fabricate shim packs Remove the mid section from the base section and install two top wear pads and a shim pack Shim the top of the mid section for a total of 1 16 inch 062 clearance Attach the extension chain to the appropriate clevis attachment point of the chain block weldment by installing the clevis pin and washer through the attach holes secure the clevis pin with a new cotter pin Place the chain block weldment in position at the aft end of the fly section secure the weldment by installing the bolts and washers JLG Lift A CAUTION WHEN ASSEMBLING BOOM SECTIONS ENSURE THAT THE BOOM SLIDING TRAJECTORIES HAVE BEEN CLEARED OF CHAINS TOOLS AND OTHER OBSTRUCTIONS 14 mid section Shim boom if necessary for a total of 1 16 inch 062 clearance NOTE Step 15 applies to 2 Section Boom Only 15 Install wear pads into the forward portion of the base section Shim boom if necessary for a total of 2 10 inch 20 clearance 16 Install wear pads into the forward portion of the mid section Shim boom if necessary for a total of 2 10 inch 20
183. sin VG4D Engine Single Viscosity Oils MS or SD When Outside Temp Use SAE is Consistently Viscosity Number 15 F 0 F 10W 40 15 F 20 20W 120 F 40 F 30 Multi Viscosity Oils MS SD SE When Outside Temp Use SAE is Consistently Viscosity Number Below Zero 5W 20 NOTE Crankcase oil should meet one of the following API classification grades SE CC SE CD SF CC SF Single Viscosity Oils CD SE CD SF When Outside Temp is Consistently 20 F 25 F 29 C to 4 C 5 F 50 F 15 C to 10 C 40 F 85 F 4 C to 30 C Above 75 F 24 C Use SAE Viscosity Number 10W 20W 20 30 40 Multi Viscosity Oils CD SE CD SF When Outside Temp is Consistently 40 F 75 F 40 C to 24 C 15 F 70 F 26 C to 21 C 15 F 85 F 26 C to 30 C 5 F 75 F 21 C to 24 C Above 5 F 21 C Use SAE Viscosity Number 5W 20 Synthetic 10W 30 10W 40 15W 30 15W 40 This viscosity can be used at colder temperatures only with engine oil preheating 1 4 JLG Lift CD Table 1 1 Hydraulic Oil Hydraulic System SAE Viscosity Operating Grade Temperature Range 0 F to 180 F 18 C to 83 C 10W 0 F to 210 F 18 C to 99 C 10W 20 10W 30 50 F to 210 F 10 C to 99 C 20W 20 NOTE Hyaraulic
184. ss drift and hammer Lightly tap end will result in loss of auxiliary power operation and of plunger with all parts assembled Recheck air less than full spool shift too little air will result in gap erratic operation it may be checked and adjusted If ai is 1 th using the procedure below If air gap is less than recommended replace nose cone assembly a With all parts assembled as shown in Figure 2 All parts must be clean and properly assembled before 31 use a depth mike or other measuring instru making these checks ment to determine the distance from the end of O RING SPACER SLEEVE 018 020 O RING AIR GAP 1ST DIMENSION 2ND DIMENSION POPPET GUIDE TUBE PLUNGER SOLENOID NOSECONE Figure 2 31 Racine Proportional Air Gap Adjustment Machines Built Prior To Mid 1987 2 58 JLG Lift 3120240 SECTION 2 PROCEDURES MEASURING POINT wr a BOOM FULLY ELEVATED AND FULLY RETRACTED FORWARD MEASURING POINT b BOOM AT HORIZONTAL AND FULLY EXTENDED Figure 2 32 Swing Bearing Tolerance Boom Placement 2 23 SWING BEARING Turntable Bearing Mounting Bolt Condition Check NOTE This check is designed to replace the existing bear ing bolt torque checks on JLG Lifts in service This check must be performed after the first 50 hours of machine operation and every 600 hours of machine operation thereafter If during this check any bolts are found to be missi
185. st control lever to REVERSE and drive machine off of block and ramp 1 Place a 6 in 15 2 cm high block with ascension 13 Have an assistant check to see that right front wheel ramp in front of left front wheel remains locked in position off of ground 2 From platform control station activate machine 14 Carefully activate SWING control lever and return hydraulic system boom to stowed position centered between drive wheels After boom reaches stowed position acti 3 Place HIGH ENGINE DRIVE SPEED and WHEEL vate DRIVE and lockout cylinders should release MOTOR SPEED control switches to their respective and allow wheel to rest on ground LOW positions 5 5 15 If lockout cylinders do not function properly 4 Place DRIVE control lever to FORWARD position qualified personnel correct the malfunction prior to and carefully drive machine up ascension ramp until left front wheel is on top of block any further operation Belleville Washers A 9101631000 Bolt and Washer ax SI ME Install Belleville Washers as shown Torque Bolt To 140 ft Ibs 190 NM 2 88 Figure 2 47 Basket Rotator Brake JLG Lift 3120240 SECTION 2 PROCEDURES 2 37 BASKET ROTATOR BRAKE SEE FIGURE 2 48 Torque belleville washers 4160026 to 140 ft Ibs 190 NM 2 38 FREE WHEELING OPTION To Disengage Drive Motors and Brakes Free Wheel for Towing etc 1 Chock
186. stall ing the jam nut and nut e Position the chain adjustment shield over the chain adjustment assembly secure the shield by installing the bolts and washers Adjust retract and extend chains to the proper torque See step a adjusting procedures of para graph 2 6 Install the hydraulic hoses electrical cables and the harnessing power track components as follows a Properly position the fly section carrier tube with carrier tube bracket installed at the side of the boom Align the attachment holes the forward end of the carrier tube with those of the fly sec tion mounting plate Secure the carrier tube by installing the bolts washers lock washers and nuts Align the support bracket with attachment holes in the mid boom and secure with bolts and washers b Properly position the assembled hoses electri cal cable and the harnessing powertrack onto the base section carrier tube Carefully feed the proper hose and cable ends through the fly sec tion carrier tube and into the hole in the boom fly section Properly align the powertrack end with the attachment point of the fly section carrier tube install the bolts washers lock washers and nuts which secure the powertrack to the car rier tube c Carefully feed the remaining hose and cable ends aft through the base section carrier tube Properly align the remaining powertrack end with the attachment point of the base section carrier tube install the bolts washers l
187. sted corrective actions technically qualified guidance should be obtained before proceeding with any maintenance Troubleshooting and maintenance information pertaining to the prime mover engine that are not contained in this manual are contained in the applicable engine mainte nance manual 3 2 TROUBLESHOOTING INFORMATION The troubleshooting procedures are listed and defined in Table 3 1 through 3 6 As an aid to table use the aerial platform is divided into six major groups each covered separately within this section These groups are as fol lows platform assembly boom assembly turntable assembly chassis assembly hydraulic system and electri cal system Each malfunction within an individual group or system is followed by a listing of probable causes which will enable determination of the applicable remedial action The prob able causes and the remedial action should where possi ble be checked in order listed in the tables It should be noted that there is no substitute for a thor ough knowledge of the equipment and related systems It should also be recognized that the majority of the prob lems arising in the machine will be centered in the hydrau lic and electrical systems For this reason every effort has been made to ensure that all likely problems in these areas are given the fullest possible treatment In the remaining machine groups only those problems which are symptomatic of greater problems of which h
188. stricted reservoir air vent Oil viscosity too high Air leak on suction side of tank Suction filter dirty Clean repair or replace line Clean or replace air vent Drain system and replace with recommended oil Refer to Hydraulic Oils Repair leak Clean or replace filter System overheating Oil viscosity too high Bypass valve not operating properly Main relief valve set too high Racine Main relief valve set too low Vickers Hydraulic system oil low Drain system and replace with recommended oil Refer to Hydraulic Oils Repair or replace valve Reset valve as required Reset valve as required Replenish oil as necessary Pump not delivering oil Restricted suction line Air entering system through broken line or fitting Broken pump drive shaft pump coupling Splines worn in drive disc Clean repair or replace line Repair or replace line or fitting Repair or replace pump pump coupling Replace drive disc 3 14 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY HYDRAULIC SYSTEM GENERAL Function sluggish during operation System pressure too low Main relief valve set too low Pump section not delivering sufficient oil Main relief valve stuck in open position Oil viscosity too low Leakin component line or fitting Scored valve spool scored cylinder Amperage too low on controlle
189. t Bleed air from brake via bleeder screw 2 29 DRIVE BRAKE AUSCO MACHINES BUILT PRIOR TO MAY 1992 SEE FIGURE 2 43 Disassembly 1 3120240 When shaft protruding downward remove bolts 23 alternately and evenly to reduce spring tension Remove power plate 20 o ring 5 stationary discs 18 springs 11 rotating discs 12 primary disc 10 pins 9 springs 6 7 and spring retainer if so equipped Further disassembly is not recommended unless necessary for the replacement of specific parts If further disassembly is required remove snap rings 1 2 then remove shaft 8 from bearing 3 by lightly tapping shaft with a plastic mallet Remove bearing from housing Remove piston 14 from the power plate 20 by intro ducing low pressure air 15 PSI into hydraulic inlet Make sure piston is directed away from operator Remove o rings 15 17 from the piston O D and I D grooves Back up rings will be damaged and should not be removed if replacement is not planned 7 Bleeder 19 can be removed and inspected to assure spring loaded ball moves freely and is free of con tamination Cleaning and Inspection 1 Clean all parts thoroughly 2 Closely inspect all parts for excessive wear cracks and chips Replace parts as necessary 3 Discard seals and o rings 4 Closely inspect bearings and bearing contact sur faces Replace as necessary NOTE Bearings may be reused if after thorough inspection they
190. table trestle Remove the bolts which secure the wear pads to the aft ends of the fly and mid sections remove the wear pads from the boom sections Steps 20 thru 28 apply to 3 Section Boom Only Remove the setscrew which secures the sheave pin at the aft end of the midsection Use a suitable brass drift to remove pin Remove sheave assembly Remove the bolts washers and bar from the trun nion pins which secure the cylinder base to the 2 15 SECTION 2 PROCEDURES boom mid section use a suitable slide hammer to remove the pins A CAUTION WHEN REMOVING THE TELESCOPE CYLINDER FROM THE BOOM IT MAY BE NECESSARY AT SOME POINT TO TURN THE CYLINDER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED WITHIN THE BOOM CARE MUST BE TAKEN TO MOVE THE CYLINDER SLOWLY FROM THE BOOM DAMAGE TO COM PONENTS MAY RESULT FROM FORCIBLE IMPACT WITH THESE ASSEMBLIES 22 23 24 NOTE 25 26 27 28 Pull the cylinder partially from the rear of the boom mid section secure the cylinder with a suitable sling and lifting device at approximately the center of gravity Carefully remove the telescope cylinder and sheave assembly Place the cylinder on a suitable trestle Remove bolts and washers from the sheave pin remove the pin and the sheave assembly Note and record the number and thickness of any wear pad shims during wear pad removal Remove the bolts which secure the wear pads to the inner surfaces of the boom
191. te boom disassem bly per instructions outlined in the 2 11 boom disassem bly every two years All boom chains and related components i e sheaves pins sprockets wear pads etc must also be inspected and replaced as necessary during this disassembly A more frequent disassembly of the boom assembly and inspection of the boom chains and related components is required if machine is exposed to hostile environments or conditions i e extreme cold dust sand blasting grit salt chemicals etc which could adversely affect boom oper ation Such a disassembly is required if either debris has accumulated inside the boom assembly or an inspection of the boom chain and related components in accor dance with the INSPECTION PROCEDURES in this sec tion reveals any discrepancies to the boom chain or related components An immediate disassembly of the boom assembly and inspection of the boom chains and related components is required if any of the following conditions occur 1 Erratic boom operation or unusual noise exists due to discrepancies listed in the INSPECTION PROCE DURES in this section to the boom chains or related components See troubleshooting section in Service Manual for probable causes 2 Chain adjustment is required more often than speci fied in Service Manual or links need to be removed chain shortened to make adjustment 3 Machine is idle for an extended period 6 months or longer 4 Boom is overlo
192. ting screw CW to improve response time Turn adjusting screw in small increments only until response time is correct Turning adjusting screw too far CW can cause surging See 6 above 2 16 ELECTRIC GOVERNOR AND ADJUSTMENTS FORD ENGINES General These instructions presume no electrical test equipment other than a multimeter for making the electrical measure ments called for on the following pages If no suitable meter is available an inexpensive but adequate meter part number 22 188 is available from any local Radio Shack store Many governor problems are due to installation prob lems particularly in first time applications Careful atten tion to the directions provided will result in a successful installation made in the least amount of time Quick start Installations If you are experienced in installing and adjusting Electric Governor follow these steps Otherwise refer to the more detailed instructions starting with Mounting Actuator 1 Mount Actuator rigidly to engine location which will permit a short straight linkage to the carburetor or fuel valve Avoid very hot areas 2 Mount controller in a dry fairly cool location Acces sibility for adjusting is required 3 Wire per appropriate included schematic using 16 wire 4 Setup fuel linkage This is critical so review the sec tion titled LINKAGE 5 Hold linkage for safety and start the engine 6 Adjust engine speed to desired v
193. to housing 21 Torque capscrews to 55 ft Ibs 75 NM If available a hydraulic press will simplify installation of end cover on housing Clamp cover in position while tightening the capscrews If hydrostatic bench testing is performed on the brake assembly release pressure should not exceed 2000 psi 137 Bar unless two additional bolts are used for supplemental clamping 2 79 SECTION 2 PROCEDURES 1 Bolts 13 2 Cover 14 Return Plate 3 Bleeder Screw 15 Springs 4 Seal Case 16 Springs 5 O Ring 17 Spring Guide 6 Back Up Ring 18 Retainer Ring 7 Piston 19 Bearing 8 O Ring 20 Dowel Pins 9 Back Up Ring 21 Housing 10 Shaft 22 Retainer Ring 11 Stator 23 Seal 12 Rotor Figure 2 43 Drive Brake Mico Machines Built From May 1992 To Machine S N 33476 2 80 JLG Lift 3120240 SECTION 2 PROCEDURES 2 31 SWING BRAKE MICO MACHINES BUILT FROM MAY 1992 TO S N 33476 SEE FIGURE 2 45 Disassembly 1 Remove end cover 2 from housing 21 by removing capscrews 1 A WARNING END COVER IS UNDER SPRING TENSION OF APPROXIMATELY 2000 POUNDS 907 KG THE FOUR CAPSCREWS SHOULD BE LOOSENED EVENLY TO RELIEVE THIS FORCE IF A HYDRAULIC PRESS IS AVAILABLE 3000 LBS 1362 KG MAXIMUM THE COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAP SCREWS 2 Remove case seal 4 from housing 21 then remove bleeder screw 3 from end cover 2 3 Remove piston 7
194. tracts erratically Hydraulic system oil low Wear pads worn Restricted or broken supply line on fitting Control valve not functioning properly Worn seal s in telescope cylinder Cylinder not functioning properly Distorted boom section s Counterbalance valve not functioning properly Replenish oil as necessary Replace pads as required Clean repair or replace line or fitting Repair or replace valve Replace seal s Repair or replace cylinder Replace distorted section s Replace counterbalance valve BOOM SWING SYSTEM response to control Hydraulic system oil low Swing control lever not functioning Restricted or broken supply line on valve bank or hydraulic pump Control valve not functioning properly Swing motor not functioning properly Swing brake not releasing Restrictor valve s plugged Foreign objects wedged between swing motor pin ionand swing gear Sheared shaft on swing motor brake Pressure reducing valve in swing circuit malfunc tioning No electric power to valve Replenish oil as necessary Repair or replace swing control lever Clean or replace line Repair or replace valve Repair or replace motor Repair or replace brake Clean or replace restrictor valve Remove objects check for damage and repair or replace component s as required Repair or replace motor brake Repair or replace pressure reducing valve See proper wiring di
195. uge Continue turning until gauge stops moving approximately 3000 PSI 206 8 Bar Turn adjustment in an addi tional 1 2 turn this will result in approximately 200 PSI 13 8 Bar higher than Drive relief setting MAIN RELIEF ADJUST PROPORTIONAL FUNCTIONS STEP 4 2 44 Figure 2 17 Vickers Proportional Valve Pressure Setting Machines Built To Present Sheet 4 of 4 JLG Lift 3120240 SECTION 2 PROCEDURES To Be Performed In Sequence Step 1 Step 2 ect Adjust To 400 PSI 31 Bar plus 50 PSI 3 4 Bar Plugger Main Relief Accessory Valve STEP 1 To Set Sequence Pressure 1 Plug pressure gauge Into quick disconnect on Vickers Valve 2 Loosen nut at main rellef and depress plugger 3 Monitor pressure gauge while making adjustments at sequence cartridge to 400 PSI 31 Bar plus or minus 50 PSI 3 4 Bar 4 Release plugger and tighten nut at main relief 5 Remove pressure gauge VICKERS VALVE Install gauge at quick disconnect on tee at lower port Figure 2 18 Vickers Proportional Valve Pressure Setting Machines Built Prior To 1989 With Accessory Valve Sheet 1 of 4 3120240 JLG Lift 2 45 SECTION 2 PROCEDURES Pressure Reducing Cartridge Adjust to 600 PSI 41 Bar plus 50 PSI 3 4 Bar Accessory Valve STEP 2 To Set Pilot Pressure 1 Plug pressure gauge into quick disconnect on Accessory Valve 2 Activate L
196. up to give satisfactory performance There is of course some overlap between these catego ries Read both sections and apply the fixes that seem appropriate NOTE During troubleshooting be prepared to control the engine manually to prevent overspeeds etc Governor won t work No reaction from Governor Actuator output arm never moved engine off or engine running Can be caused by 1 No power Incorrect linkage preventing movement 2 3 Incorrect electrical hook up 4 No speed signal to Governor 5 Damaged Controller or Actuator 1 No power Use a multimeter to check for 12 15 VDC between terminals A amp B on the controller Check during engine off and engine running conditions If voltage is absent or low check for Wiring error Hook up on wrong side of ballast resistor Low battery Bad voltage regulator Bad ground connection corroded terminals g Undersized wiring 2 Incorrect Linkage Re check linkage as discussed on page 40 and 41 Freedom of movement and lack of play are important 3 Incorrect Electrical Hook up Re check all wiring and connections to the Actuator and Controller against the supplied schematic 4 No speed signal to Controller a Check the voltage between terminals C and ground and D and ground of the 8 pin connector with the engine running You should see 5 30 VDC 2 28 JLG Lift b The above checks do not guarantee
197. ure release section of brake by pressur izing side inlet port and allowing air to escape from top port Pressure should not exceed 100 psi 6 9 Bar during bleeding Apply sufficient pressure to release brake and check for proper operation 3120240 SECTION 2 PROCEDURES 2 28 SWING DRIVE BRAKE AUSCO MACHINES BUILT PRIOR TO MAY 1992 SEE FIGURE 2 41 Disassembly 1 10 11 3120240 With shaft protruding downward remove bolts 22 alternately and evenly to reduce spring tension Remove power plate 21 and gasket 2 Bearing 18 is pressed onto shaft 7 and must be removed before removal of rotating discs 11 and stationary discs 12 Further disassembly is not recommended unless necessary for the replacement of specific parts If further disassembly is required remove shaft 7 and stack sub assembly from housing 1 by lightly tapping or pressing on the small external spline end of the shaft and removing the shaft bearings and stack from housing Remove bearing 18 stationary disc 12 rotating disc 11 springs 10 and primary disc 9 Remove bearing 3 from shaft using care not to dam age seal 4 Remove seal 4 Remove springs 6 and spring retainer 5 from hous ing Remove piston 13 from power plate by introducing low pressure air 15 PSI into hydraulic inlet Direct piston away from operator Remove o rings 15 17 and back up rings 14 16 from piston O D and 1 0 grooves Back up rings will be dam
198. ustments replace cover Mount so that water cannot pool on this cover Always mount the controller with the strain relief down This will prevent water from entering thru the cable also place the vent hole in the bottom of the controller down Wiring See wiring diagram for details of hook up Use 16 wire minimum Keep all wiring to the Governor as short as is practical Go directly from the controller ground terminal B of the 8 pin connector by dedicated wire to the battery minus terminal If this cannot be done for some reason go by dedicated wire to a very good engine ground A properly functioning engine electrical system will supply 13 5 14 8 VDC when the engine is running If wiring size is adequate with good connections and proper grounds you will get this reading between the wires terminals A amp B of the 8 pin connector when the Governor is controlling engine speed Verify this Improper hook up can damage electronics Re check wiring before applying power Power Distribution 8 Pin Connector Pin a 12 VDC from the make before break oil pressure Switch This switch provides power to pin A when the ignition is on and the engine is running no oil pressure or when the engine is off when the engines running has oil pressure Ground Tach signal from the engine ignition system Tach signal from the engine ignition system Control signal to operate the Actuator Control signal to operate th
199. ve starter motor Damaged wiring in ignition circuit broken wire on starter Ignition switch not functioning properly Ignition relay notfunctioning properly Ignition circuit shorted to ground Battery cable s not making contact Actuate switch as required Determine and correct cause reset circuit breaker Replace starter motor Repair replace wiring Replace switch Replace relay See proper wiring diagram Clean and tighten cable s Engine will not start Ignition No fuel Clogged fuel filter Restricted or broken fuel line Automatic choke out of adjustment Battery discharged Fuel pump not working Replenish fuel as necessary Replace fuel filter Clean or replace fuel line Adjust choke Charge battery replace if defective Replace fuel pump 3120240 JLG Lift 3 7 SECTION 3 TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY Engine will notaccelerate above low speed Damaged wiring on speed control switch or high engine solenoid Speed control switch not functioning properly High engine solenoid not functioning properly High engine circuit breaker not functioning prop erly Switch not functioning properly or improperly adjusted Excessive load on engine Engine worn badly Engine improperly timed Dirty fuel filter diesel Fuelline pinched diesel Throttle governor not working properly Repair replace wir
200. vis from the chain Removal and disassemble of the retraction chain attachment and adjustment assembly as follows a Remove nuts and washers from the chain attachment shield and remove shield from the boom base section b Remove the jam nut and nut from the threaded end of the tension adjusting clevis bolt Remove the entire tension adjusting assembly from the boom mounted bracket c Remove the cotter pins from the clevis pins which secure the retraction chains to the clevis bolt assembly d Remove cotter pins nuts and bolts securing chain attach blocks to clevis bolt assembly Remove attach blocks e Separate top and bottom clevis bolt assembly plates Remove clevis bolt from bottom plate Remove the setscrews from the pin which attaches the telescope cylinder rod end to the boom base section use a brass drift to remove the pin Note and record the number and thickness of any wear pad shims during wear pad removal Remove bolts which secure the wear pads to the inner forward surfaces of the boom base section Remove the wear pads from the top sides and bot tom of the boom base section Steps 10 thru 15 apply to 3 Section Boom Only 10 11 12 Using suitable lifting equipment carefully slide the assembled mid and fly sections from the base sec tion Place the mid and fly sections on a suitable trestle Remove the setscrew which secures the sheave pin at the aft end of the midsection Use a suitab
201. will assure that they are correctly reinstalled Hydraulic System 1 Keep the system clean If evidence of metal or rub ber particles are found in the hydraulic system drain and flush the entire system 2 Disassemble and reassemble parts on clean work surface Clean all metal parts with non flammable cleaning solvent Lubricate components as required to aid assembly Lubrication Service applicable components with the amount type and grade of lubricant recommended in this manual at the specified intervals When recommended lubricants are not available consult your local supplier for an equivalent that meets or exceeds the specifications listed 2 2 Battery Clean battery using a non metallic brush and a solution of baking soda and water Rinse with clean water After cleaning thoroughly dry battery and coat terminals with an anti corrosion compound Lubrication and Servicing Components and assemblies requiring lubrication and servicing are shown in Figures 1 2 2 3 LUBRICATION INFORMATION Hydraulic System JLG Lift 1 The primary enemy of a hydraulic system is contam ination Contaminants enter the system by various means e g using inadequate hydraulic oil allowing moisture grease filings sealing components sand etc to enter when performing maintenance or by permitting the pump to cavitate due to insufficient system warm up or leaks in the pump supply suc tion
202. wiring on level limit switch Repair or replace wiring dose not operate below horizontal Solenoid failure Replace solenoid Tripped circuit breaker Resetcircuit breaker Damaged level switch Replace switch repair or replace holder Defective relay main terminal box Replace relay Defective platform switch Replace switch TELESCOPE SYSTEM Noresponseto control Telescope control inoperative Hydraulic system oil low Damaged wiring on control switch or solenoid valve Control valve not functioning properly Restricted or broken supply line on valve bank or hydraulic pump Telescope cylinder not functioning properly Hydraulic pump not functioning properly Repair or replace control valve Replenish oil as necessary Repair or replace wiring Repair or replace valve Clean or replace line Repair or replace cylinder Repair or replace pump 3 4 JLG Lift 3120240 SECTION 3 TROUBLESHOOTING TROUBLE PROBABLE CAUSE REMEDY Boom will not extend Control valve not functioning properly Damaged wiring on control switch or solenoid valve Restricted or broken supply line on fitting Pressure setting incorrect Telescope cylinder not functioning properly Repair or replace control valve Repair or replace wiring Clean repair or replace line or fitting Check pressure readjust as necessary Repair or replace cylinder Boom extends and re
203. with hydraulic control valves move control lever for applicable cylinder in each direction This is done to relieve pressure in the hydraulic lines Carefully remove hydraulic hoses from appropriate cylinder port block 4 There will be initial weeping of hydraulic fluid which can be caught in a suitable container After the initial discharge there should not be any further leakage from the ports If leakage continues at a rate of 6 8 drops per minute or more the counterbalance valve is defective and must be replaced 5 check piston seals carefully remove the counter balance valve from the retract port After initial dis charge there should not be any further leakage from the ports If leakage occurs at a rate of 6 8 drops per minute or more the piston seals are defective and must be replaced 6 If no repairs are necessary or when repairs have been made replace counterbalance valve and care fully connect hydraulic hoses to cylinder port block 7 If used remove lifting device from upright or remove prop from below boom activate hydraulic system and run cylinder through one complete cycle to check for leaks 3120240 2 9 CYLINDER REPAIR NOTE The following are general procedures that apply to all of the cylinders on this machine Procedures that apply to a specific cylinder will be so noted Disassembly A IMPORTANT DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON A CLEAN WORK SURFACE IN A DIRT FREE WORK A
204. y a coat of grease or petroleum jelly to clus ter gear bore i Place sixteen needle rollers into cluster gear bore j Place spacer into opposite side of cluster gear and against needle rollers k Place second set of sixteen needle rollers into cluster gear Apply grease or petroleum jelly to tang side of two thrust washers Place thrust washers against bosses in carrier with washer tang fitting into slot in carrier outside diameter m While keeping thrust washers in place slide cluster gear into carrier with larger gear on side with small pin hole n Line up cluster gear and thrust washers with hole in carrier and slide planet shaft through Ensure chamfered side of hole in planet shaft is lined up with pin hole in carrier Drive anti roll pin flush into carrier hole locking planet shaft into place p Repeat steps h through o for remaining two clus ter gears Input Shaft Assembly A CAUTION EYE PROTECTION SHOULD BE WORN DURING RETAINING RING REMOVAL AND INSTALLATION a Carefully remove retaining ring 17 from input shaft 14 and discard retaining ring b Remove two spacers 17 and spring 16 from input shaft c Clean and inspect all parts in accordance with paragraph b Replace parts as necessary d Place washer 15 spring 16 and washer 15 in that order onto input shaft e Install retaining ring into input shaft groove to secure spacers and spring to shaft Assembly 1 JLG
205. y the outside plates for cracks in line with the pins If cracks are found replace the chain if no cracks are discovered lubricate the chains by dipping in heated oil and reinstall on the machine Keep chains lubricated Fatigue Cracks Fatigue is a phenomenon that affects most metals and is the most common cause of chain plate failures Fatigue cracks are found through the link holes perpendicular 90 degrees from the Minimum plate depth 850 047 903 Lubrication One of the most important but often overlooked factors is adequate lubrication In addition to reducing internal friction maintaining 3120240 JLG Lift 2 5 SECTION 2 PROCEDURES pin in line position Inspect chains carefully after long time use and heavy loading for this type of crack If any cracks are discovered replace all chains as seemingly sound plates are on the verge of cracking Fatigue and ultimate strength failures on JLG Lifts are incurred as a result of severe abuse as design specs are well within the rated lifting capacity of these chains 2 6 CD Tight Joints All joints in the roller chain should flex freely On roller chain tight joints are usually caused by rust corrosion or the inside plates walking off the bushing Limber up rusty cor roded chains after inspecting care fully with a heavy application of oil preferably a hot oil dip Tap inside walking plates inward if walking persists
206. you suspect that you may have over adjusted the high engine pot or have lost track of where you are turn the pot 25 to 30 turns out CCW then turn in CW 10 turns This will get you back into the range you should be in Make the high engine adjustment first then gain then reset high engine Gain This adjustment is made by turning the plastic screw clockwise CW to increase governor sensitivity counter clockwise CCW to decrease sensitivity The adjustment range of the Factory pot is about 3 4 of a turn AND OVER TURNING WILL BREAK THE INTERNAL STOPS making further adjustments impossible Too much gain will cause instability and the engine will pulsate Not enough gain will make the engine slow to respond to load requirements and at first appears to be a good setting when operating directional functions other than drive The engine will accelerate right up to the set RPMS and stop at that point The problem with this type of gain setting is that when a large load is applied usually thru drive and then suddenly unloaded the engine will be slow to respond in decreasing RPMS This will cause the engine to over rev and then at times will activate the over speed cutout and shut the engine off The ideal gain setting will provide a compromise between quick response and good stability This will usually show up as 1 to 3 engine pulsation s 3120240 SECTION 2 PROCEDURES 3120240 before leveling out at the set RPMS when going

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